Electrochemical Module, Electrochemical Device, and Energy System

ABSTRACT

An electrochemical module including, a stack obtained by stacking, in a predetermined stacking direction, a plurality of electrochemical elements having a configuration in which an electrode layer, an electrolyte layer, and a counter electrode layer are formed along a substrate, via an annular sealing portion through which first gas, that is one of reducing component gas and oxidative component gas, flows; a container including an upper cover for pressing a first flat face in the stacking direction of the stack and a lower cover for pressing a second flat face on a side opposite to the first flat face, the stack clamped between the upper cover and the lower cover; an elastic lower plate-like member arranged between the first flat face and the upper cover; and a first gas supply portion and a first gas discharge portion connected to the second flat face in communication with the annular sealing portion.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is the United States national phase of International Application No. PCT/JP2020/014330 filed Mar. 27, 2020, and claims priority to Japanese Patent Application No. 2019-069391 filed Mar. 29, 2019, the disclosures of which are hereby incorporated by reference in their entirety.

BACKGROUND OF THE INVENTION 1. Field of the Invention

The present invention relates to an electrochemical module, an electrochemical device, and an energy system.

2. Description of Related Art

A fuel cell stack as disclosed in Japanese Patent Application Publication No. JP 2015-153679A (Patent Document 1) and Japanese Patent Application Publication No. JP 2016-62852A (Patent Document 2) is configured as a stack obtained by stacking a plurality of power generating cells. The stack is sandwiched between two rectangular end plates arranged at the two ends in the stacking direction of the stack. Connection bars extending in the stacking direction of the stack are arranged between the two end plates and support each of the two end plates at four positions in the peripheral edge portion thereof. The two ends of each of the connection bars are fixed to the two end plates using bolts. Accordingly, the two end plates are supported and fixed by the connection bars that are fixed to four positions in the peripheral portion of each of the end plates, and clamp the stack sandwiched between the two end plates. Thus, clamping pressure in the stacking direction is applied to the stack, so that an increase in internal resistance and a decrease in the ability to seal in reaction gas are suppressed, and a plurality of power generating cells are formed into an integrated stack.

SUMMARY OF THE INVENTION

In Patent Documents 1 and 2, the end plates clamp the stack in the state in which each end plate is in contact with the entire surface of the stack, and therefore, substantially uniform clamping pressure is applied to the whole stack. However, the stack includes a region on which an electrode structure that includes a cathode, an anode, and an electrolyte is stacked, and a region on which a supply/discharge unit for supplying gas to be used in a power generating reaction to the electrode structure and discharging the gas from the electrode structure is provided. The supply/discharge unit has a configuration in which annular articles that are provided corresponding to a plurality of electrode structures are linked together in the stacking direction as the electrode structures are stacked. For example, if sufficient clamping pressure is applied to the region on which the electrode structures are stacked, but insufficient clamping pressure is applied to the region on which the supply/discharge unit is provided, a gap is generated between the annular article and a member that is in contact with the annular article. In this case, the gas leaks through this gap.

Therefore, when a gas flow passage having a configuration in which a plurality of members are stacked in a stacking direction is provided, it is desired to suppress generation of gaps in contact portions where these members and other members are in contact and thus suppress gas leakage.

Accordingly, the present invention was achieved in light of the aforementioned problems, and it is an object thereof to provide an electrochemical module capable of suppressing generation of a gap between a member through which gas flows in a stacking direction and another member and thus suppressing gas leakage, an electrochemical device, and an energy system.

A characteristic configuration of an electrochemical module according to the present invention includes:

a stack obtained by stacking, in a predetermined stacking direction, a plurality of electrochemical elements having a configuration in which an electrolyte layer, and an electrode layer and a counter electrode layer that are respectively arranged on two sides of the electrolyte layer, are formed along a substrate, via an annular sealing portion through which first gas that is one of reducing component gas and oxidative component gas flows;

a clamp that includes a first clamping portion for pressing a first flat face in the stacking direction of the stack and a second clamping portion for pressing a second flat face on a side opposite to the first flat face, the stack being clamped between the first clamping portion and the second clamping portion;

an elastic first plate-like member arranged between the first flat face and the first clamping portion; and

a flowing pipe connected to the second flat face in a state of being in communication with the annular sealing portion.

Reducing component gas or oxidative component gas flows through the annular sealing portion. If a pressing force applied to the annular sealing portion is insufficient, the first gas will leak through a gap generated in a contact portion where the annular sealing portion and another member are in contact. For example, the plurality of electrochemical elements are stacked in the stacking direction and pressed with predetermined clamping pressure, but a pressing force required for the annular sealing portion may be larger than a pressing force applied to an electrochemical reaction portion that includes the electrode layer, the electrolyte layer, and the counter electrode layer.

More specifically, the electrochemical element includes the electrode layer, the electrolyte layer, and the counter electrode layer that are formed along the substrate. The electrode layer, the electrolyte layer, and the counter electrode layer serve as the electrochemical reaction portion in which an electrochemical reaction occurs due to supply of the first gas, and the like. The stack is formed by stacking, in a predetermined stacking direction, the plurality of electrochemical elements with the annular sealing portion being provided therebetween and by pressing them with predetermined clamping pressure.

In this case, due to a difference in the configuration, a pressing force applied to the region on which the electrochemical reaction portions are present and a pressing force applied to the region on which the annular sealing portions are present may be different from each other in the stack. A pressing force required for the region on which the annular sealing portions are present may be larger than a pressing force applied to the region on which the electrochemical reaction portions are present. In this case, if no more than pressing force required for the electrochemical reaction portion is applied to the stack, the annular sealing portion will not be pressed with a required pressing force. As a result, a gap will be generated in a contact portion where the annular sealing portion and another member are in contact, and the first gas will leak through the gap.

With the characteristic configuration above, the stack is pressed by the elastic first plate-like member from the first flat face side of the stack. On the other hand, the flowing pipe that is in communication with the annular sealing portion through which the first gas flows is provided on the second flat face side of the stack. Accordingly, the stack is pressed by the first plate-like member toward the piping including a supply pipe, a discharge pipe, and the like to which the annular sealing portion is coupled. Thus, leakage of the first gas through a gap between the annular sealing portion and another member can be suppressed.

Moreover, the stack is pressed by the first plate-like member from the first flat face side toward the second flat face side on which the flowing pipe is provided, and thus a connection position where the stack and the flowing pipe are connected to each other can be substantially fixed. Thus, the annular sealing portion and the flowing pipe can be fixed to each other through welding or the like. Accordingly, there is no need to use flexible piping in consideration of a shift of the connection position where the annular sealing portion and the flowing pipe are connected to each other, and thus a common durable stainless steel pipe or the like can be used for the piping.

It should be noted that, even if a clearance between the stack and the clamp and the like changes due to expansion or contraction of the stack and the like, this change is compensated with the elastic first plate-like member. That is, when at least one of the stack and the clamp expands, a clearance between the stack and the clamp may change between before and after expansion of the stack and the like. The first plate-like member has elasticity, and therefore, the stack is elastically clamped between the two clamping portions due to the elastic force even if the clearance between the stack and the clamp changes. Accordingly, appropriate clamping pressure in the stacking direction can be applied to the stack.

Another characteristic configuration of the electrochemical module according to the present invention further includes

an elastic second plate-like member arranged between the second flat face and the second clamping portion,

wherein elastic force of the first plate-like member is larger than elastic force of the second plate-like member.

The expression “elastic force is large” as used herein means that, even if the plate-like member itself is elastically deformed, a decrease in elastic force generated by the plate-like member is small.

The stack is pressed by the elastic first plate-like member from the first flat face side of the stack and by the elastic second plate-like member from the second flat face side of the stack. The flowing pipe that is in communication with the annular sealing portion through which the first gas flows is provided on the second flat face side of the stack. Since the elastic force of the first plate-like member is larger than the elastic force of the second plate-like member, the stack is pressed by the first plate-like member toward the piping including a supply pipe, a discharge pipe, and the like to which the annular sealing portion is coupled. Thus, the connection position where the stack and the flowing pipe are connected to each other can be substantially fixed, and leakage of the first gas through a gap between the annular sealing portion and another member can be suppressed.

It should be noted that a relationship “the elastic force of the first plate-like member>the elastic force of the second plate-like member” can be achieved by setting a relationship “the thermal expansion rate of the first plate-like member>the thermal expansion rate of the second plate-like member”.

Another characteristic configuration of the electrochemical module according to the present invention further includes

a pressing mechanism that is provided on the second flat face side and presses a portion to which the annular sealing portion is attached against the clamp in the stacking direction.

With the characteristic configuration above, the stack is pressed by the first plate-like member located on the first flat face side of the stack harder from the first flat face side than from the second flat face side. Accordingly, the stack is pressed by the first plate-like member toward the piping including a supply pipe, a discharge pipe, and the like to which the annular sealing portion is coupled. Furthermore, with the characteristic configuration above, the electrochemical module includes the pressing mechanism for pressing the annular sealing portion in the stacking direction, and therefore, the annular sealing portion can be pressed, and thus leakage of the first gas through the gap between the annular sealing portion and another member can be suppressed. Moreover, since the annular sealing portion can be pressed independently of the electrochemical reaction portion, an appropriate pressing force capable of suppressing leakage of the first gas through the gap between the annular sealing portion and another member can be applied to the annular sealing portion.

In another characteristic configuration of the electrochemical module according to the present invention,

wherein the pressing mechanism presses, via the flowing pipe, a region in which the annular sealing portion is present in the stacking direction, and

a thermal expansion rate of the pressing mechanism is smaller than or equal to a thermal expansion rate of the flowing pipe.

With the characteristic configuration above, the thermal expansion rate of the pressing mechanism is smaller than or equal to the thermal expansion rate of the flowing pipe, thus making it possible to suppress loss in transmission of a pressing force from the pressing mechanism to the annular sealing portion via the flowing pipe. For example, a case is assumed where the thermal expansion rate of the pressing mechanism is larger than the thermal expansion rate of the flowing pipe. If the pressing mechanism thermally expands in a direction different from the direction in which the flowing pipe and the annular sealing portion are to be pressed by the pressing mechanism, the flowing pipe cannot follow the expansion of the pressing mechanism in some cases. Accordingly, a clearance between the pressing mechanism and the flowing pipe increases in size, and thus the pressing mechanism cannot sufficiently transmit a pressing force to the annular sealing portion via the flowing pipe.

In another characteristic configuration of the electrochemical module according to the present invention,

the pressing mechanism includes a first screw member provided on the first clamping portion, and a second screw member that can press the annular sealing portion in the stacking direction when screwed to the first screw member.

With the characteristic configuration above, screwing the first screw member and the second screw member included in the pressing mechanism to each other makes it possible to press the annular sealing portion in the stacking direction and suppress leakage of the first gas through the gap between the annular sealing portion and another member.

In another characteristic configuration of the electrochemical module according to the present invention,

the first screw member is a cylindrical member provided with an internal thread portion on an inner circumferential face,

the second screw member is a cylindrical member provided with an external thread portion on an outer circumferential face, and

the external thread portion of the second screw member is screwed to the internal thread portion of the first screw member.

With the characteristic configuration above, screwing the external thread portion of the second screw member to the internal thread portion of the first screw member makes it possible to press the annular sealing portion in the stacking direction and suppress leakage of the first gas through the gap between the annular sealing portion and another member.

In another characteristic configuration of the electrochemical module according to the present invention,

the pressing mechanism further includes an electrical insulating sealing portion between the second screw member and the flowing pipe.

With the characteristic configuration above, the gap between the second screw member and the annular sealing portion is sealed with the sealing portion, thus making it possible to suppress leakage of the first gas between the second screw member and the annular sealing portion. Moreover, the sealing portion has an insulating ability, and thus electric short (short circuit) can be suppressed in the electrochemical module.

In another characteristic configuration of the electrochemical module according to the present invention,

the substrate includes, thereinside, an internal passage into which the first gas is introduced through the annular sealing portion, and

a flowing portion through which second gas that is the other of the reducing component gas and the oxidative component gas flows is formed between the electrochemical elements that are adjacent to each other in the stacking direction.

With the characteristic configuration above, in each of the electrochemical elements, the internal passage through which the first gas flows is formed inside the substrate, and the flowing portion through which the second gas flows is formed between the adjacent electrochemical elements. Accordingly, in the electrochemical elements, the first gas supplied from the internal passage and the second gas supplied from the flowing portion react with each other to cause an electrochemical reaction, and thus electrical power can be generated.

In another characteristic configuration of the electrochemical module according to the present invention,

the substrate of each electrochemical element includes a first penetrated portion for forming a supply passage through which the first gas flows, and

the first penetrated portion of each electrochemical element is in communication with an annular hole of the annular sealing portion provided between the adjacent electrochemical elements.

With the characteristic configuration above, the first gas is supplied to the stack through the first penetrated portion of each electrochemical element and the annular sealing portion.

In another characteristic configuration of the electrochemical module according to the present invention,

a first electrochemical element and a second electrochemical element among the plurality of electrochemical elements are adjacently stacked,

the substrate included in each electrochemical element includes, thereinside, an internal passage into which the first gas flows through the annular sealing portion,

the substrate included in the first electrochemical element and the substrate included in the second electrochemical element are opposed to each other, an outer face of the substrate included in the first electrochemical element on which an electrochemical reaction portion is arranged is electrically connected to an outer face of the substrate included in the second electrochemical element that is different from an outer face on which the electrochemical reaction portion is arranged, and a flowing portion through which second gas that is the other of the reducing component gas and the oxidative component gas flows is formed between the two adjacent outer faces along the two outer faces.

With the characteristic configuration above, each of the electrochemical elements includes the internal passage inside the substrate, and the first gas flows through the internal passage. On the other hand, the second gas flows through the flowing portion that is separated from the internal passage. Accordingly, the flow of the first gas and the flow of the second gas can be separated.

In another characteristic configuration of the electrochemical module according to the present invention,

the substrate included in each electrochemical element is provided with a gas-permeable portion through which gas is permeable between the internal passage, which is located inside the substrate, and the outside,

the electrode layer, the electrolyte layer, and the counter electrode layer form an electrochemical reaction portion in a state in which the electrochemical reaction portion entirely or partially covers the gas-permeable portion, and

a first penetrated portion for forming a supply passage through which the first gas flows is formed between the outside in a surface penetration direction of the substrate and the internal passage.

When the electrochemical elements are allowed to function as fuel cells (electrochemical power generating cells) that “convert chemical energy such as fuel into electric energy”, the first gas is one of reducing component gas such as hydrogen gas and oxidative component gas such as air that are to be consumed in an electrochemical reaction, and the second gas is the other.

When the electrochemical elements are allowed to function as electrolysis cells that “convert electric energy into chemical energy such as fuel”, the first gas is one of reducing component gas such as hydrogen gas and oxidative component gas such as oxygen that are to be generated in an electrochemical reaction, and the second gas is the other.

Moreover, the substrate includes the gas-permeable portion through which gas is permeable between the internal passage, which is located inside the substrate, and the outside, and the electrochemical reaction portion that entirely or partially covers the gas-permeable portion and includes the electrode layer, the electrolyte layer, and the counter electrode layer. Accordingly, when the electrochemical elements are allowed to function as fuel cells (electrochemical power generating cells), the first gas and the second gas reach the electrochemical reaction portion through a route from the outside of the substrate and a route that connects the internal passage and the gas-permeable portion of the substrate, and react with each other in the electrode layer and the counter electrode layer, thus making it possible to cause an electrochemical reaction for generating electric power, for example.

When the electrochemical elements are allowed to function as electrolysis cells, the first gas and the second gas can be generated through an electrolytic reaction of water or the like by supplying electricity to the electrochemical reaction portion, and discharged through the route on the outside of the substrate and the route that connects the gas-permeable portion of the substrate and the internal passage.

Another characteristic configuration of the electrochemical module according to the present invention includes,

in the flowing portion, a first annular sealing portion serving as the annular sealing portion for separating the first penetrated portion formed in each of the two outer faces from the flowing portion,

wherein the supply passage for supplying the first gas to the internal passage is formed by the first penetrated portion and the first annular sealing portion.

Providing the first annular sealing portion makes it possible to connect the first penetrated portions of the electrochemical elements stacked in the stack such that the first penetrated portions are in communication with each other in a state of being separated from the flowing portion. Accordingly, employing a very simple configuration in which the first penetrated portions of the adjacent electrochemical elements are connected to each other in a gastight manner makes it possible to connect the electrochemical elements such that the electrochemical elements appropriately operate using the first gas and the second gas. Therefore, the electrochemical elements can be used to form an electrochemical module that can be easily produced and is reliable. Also, the electrochemical element has a structure that is easy to handle during the production of the electrochemical module.

There is no limitation on the shape of the annular sealing portion as long as a configuration is obtained in which the penetrated portions are in communication with each other and leakage of gas can be prevented. That is, it is sufficient that the annular sealing portion has an endless shape provided with an opening portion that is in communication with the penetrated portion therein, and is configured to seal a gap between the adjacent electrochemical elements. The annular sealing portion has, for example, an annular shape. The annular shape may be any of an annular circle, an annular ellipse, an annular square, an annular polygon, and the like.

In another characteristic configuration of the electrochemical module according to the present invention,

the substrate includes a second penetrated portion for forming a discharge passage through which the first gas that has passed through the internal passage flows to the outside in a surface penetration direction of the substrate,

the electrochemical module further includes, in the flowing portion, a second annular sealing portion serving as the annular sealing portion for separating the second penetrated portion formed in each of the two outer faces from the flowing portion, and

the discharge passage through which the first gas that has passed through the internal passage flows is formed by the second penetrated portion and the second annular sealing portion.

That is, for example, when the electrochemical elements are allowed to function as fuel cells (electrochemical power generating cells), the first gas that has entered the internal passage from the first penetrated portion flows through the internal passage to the electrochemical reaction portion via the gas permeable portion, and the remainder flows into the second penetrated portion that forms a discharge passage. The discharge passage is formed in the state in which the second penetrated portion is separated from the second gas, and thus the first gas can be collected from the discharge passage independently of the second gas. This discharge passage is formed by a sealing portion as in the case of the supply passage formed by the first penetrated portion. Accordingly, employing a very simple configuration in which the second penetrated portions of the adjacent electrochemical elements are connected to each other in a gastight manner makes it possible to connect the electrochemical elements such that the second penetrated portions are in communication with each other in a state of being separated from the flowing portions, and the electrochemical elements appropriately operate using the first gas and the second gas. Therefore, the electrochemical elements can be used to form an electrochemical module that can be easily produced and is reliable. Also, the electrochemical element has a structure that is easy to handle during the production of the electrochemical module.

A characteristic configuration of an electrochemical device according to the present invention includes at least:

the electrochemical module as mentioned above; and

a fuel converter that supplies gas containing a reducing component to the electrochemical module or a fuel converter that converts gas containing a reducing component generated in the electrochemical module.

With the characteristic configuration above, the electrochemical module and the fuel converter that allows gas containing a reducing component to flow to the electrochemical module are provided. Accordingly, in the case of operating the electrochemical module as a fuel cell, employing a configuration in which hydrogen is generated using a fuel converter such as a reformer from natural gas or the like supplied using an existing raw fuel supply infrastructure such as city gas and is allowed to flow to the fuel cell makes it possible to realize an electrochemical device that includes an electrochemical module with excellent durability, reliability, and performance. Also, it is easier to construct a system that recycles unused fuel gas discharged from the electrochemical module, thus making it possible to realize a highly efficient electrochemical device.

Furthermore, with the characteristic configuration above, the electrochemical module and the fuel converter that converts gas containing a reducing component generated in the electrochemical module are provided. Accordingly, in the case of operating the electrochemical module as an electrolysis cell, an electrochemical device can be obtained in which hydrogen generated through an electrolytic reaction of water is reacted with carbon monoxide or carbon dioxide and converted into methane or the like using the fuel converter, for example. Employing such a configuration makes it possible to realize an electrochemical device that includes an electrochemical module with excellent durability, reliability, and performance.

A characteristic configuration of an electrochemical device according to the present invention includes at least:

the electrochemical module as mentioned above; and

a power converter that extracts power from the electrochemical module or supplies power to the electrochemical module.

With the characteristic configuration above, the power converter extracts power generated by the electrochemical module or supplies power to the electrochemical module. Thus, as mentioned above, the electrochemical module serves as a fuel cell or an electrolysis cell. Accordingly, with the configuration above, it is possible to provide an electrochemical module and the like that can improve the efficiency of converting chemical energy such as fuel into electric energy or can improve the efficiency of converting electric energy into chemical energy such as fuel.

It should be noted that it is preferable to use an inverter as the power converter, for example, because the inverter can be used to boost electrical output obtained from the electrochemical module with excellent durability, reliability, and performance, and to convert a direct current into an alternating current, thus making it easy to use the electrical output obtained from the electrochemical module.

A characteristic configuration of an energy system according to the present invention includes:

the electrochemical device as mentioned above; and a waste heat utilization system that reuses heat discharged from the electrochemical device or a fuel converter.

With the characteristic configuration above, the electrochemical device and the waste heat utilization system that reuses heat discharged from the electrochemical device or the fuel converter are provided, thus making it possible to realize an energy system that has excellent durability, reliability, and performance as well as excellent energy efficiency. It should be noted that it is also possible to realize a hybrid system that has excellent energy efficiency by combination with a power generation system that generates power with use of combustion heat from unused fuel gas discharged from the electrochemical device or the fuel converter.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross-sectional view of an electrochemical module.

FIG. 2 is a top view of the electrochemical module.

FIG. 3 is a side view of the electrochemical module.

FIG. 4 is a schematic view of the electrochemical module.

FIG. 5 is a cross-sectional view of an electrochemical module according to another aspect 1.

FIG. 6 is a cross-sectional view of an electrochemical module according to another aspect 2.

FIG. 7 is a top view of the electrochemical module shown in FIG. 6.

FIG. 8 is a side view of the electrochemical module shown in FIG. 6.

FIG. 9 is a schematic view of an electrochemical element.

FIG. 10 is a cross-sectional view taken along line X-X in FIG. 9.

FIG. 11 is a cross-sectional view taken along line XI-XI in FIG. 9.

FIG. 12 is a cross-sectional view taken along line XII-XII in FIG. 9.

FIG. 13 is a cross-sectional view taken along line XIII-XIII in FIG. 9.

FIG. 14 is a cross-sectional view taken along line XIV-XIV in FIG. 9.

FIG. 15 is a cross-sectional view taken along line XV-XV in FIG. 9.

FIG. 16 is a cross-sectional view taken along line XVI-XVI in FIG. 9.

FIG. 17 is a cross-sectional view taken along line XVII-XVII in FIG. 9.

FIG. 18 is an enlarged view of a relevant portion of an electrochemical reaction portion.

FIG. 19 is a schematic view of an energy system.

FIG. 20 is a cross-sectional view of an electrochemical module.

FIG. 21 is a top view of the electrochemical module.

FIG. 22 is a side view of the electrochemical module.

FIG. 23 is a schematic view of the electrochemical module.

FIG. 24 is a cross-sectional view of an electrochemical module.

FIG. 25 is an explanatory diagram of an electrochemical module according to another aspect.

FIG. 26 is a schematic view of another energy system.

FIG. 27 is a schematic view of another electrochemical element.

FIG. 28 is a cross-sectional view taken along line XXVIII-XXVIII in FIG. 27.

FIG. 29 is a cross-sectional view taken along line XXIX-XXIX in FIG. 27.

FIG. 30 is a cross-sectional view taken along line XXX-XXX in FIG. 27.

FIG. 31 is a cross-sectional view taken along line XXXI-XXXI in FIG. 27.

FIG. 32 is a cross-sectional view taken along line XXXII-XXXII in FIG. 27.

FIG. 33 is a cross-sectional view taken along line XXXIII-XXXIII in FIG. 27.

FIG. 34 is a cross-sectional view taken along line XXXIV-XXXIV in FIG. 27.

FIG. 35 is a cross-sectional view taken along line XXXV-XXXV in FIG. 27.

FIG. 36 is a cross-sectional view taken along line XXXVI-XXXVI in FIG. 27.

FIG. 37 is a cross-sectional view taken along line XXXVII-XXXVII in FIG. 27.

FIG. 38 is a cross-sectional view taken along line XXXVIII-XXXVIII in FIG. 27.

FIG. 39 is a cross-sectional view taken along line XXXIX-XXXIX in FIG. 27.

FIG. 40 is a cross-sectional view taken along line XL-XL in FIG. 27.

FIG. 41 is a cross-sectional view taken along line XLI-XLI in FIG. 27.

FIG. 42 is a cross-sectional view taken along line XLII-XLII in FIG. 27.

FIG. 43 is an enlarged view of a relevant portion of an electrochemical reaction portion.

FIG. 44 is an explanatory diagram of a supply structure and a discharge structure.

DESCRIPTION OF THE INVENTION

Hereinafter, an electrochemical module M according to an embodiment of the present invention will be described. It should be noted that when the positional relationship between layers and the like are described, an electrolyte layer side is referred to as “upper portion” or “upper side”, and a first plate-like body side is referred to as “lower portion” or “lower side”, with respect to an electrode layer, for example. The effect of the present invention in the case where the electrochemical module M is arranged extending in the vertical direction is the same as that in the case where the electrochemical module M is arranged extending in the horizontal direction, and therefore, “upper” and “lower” may be read as “left” and “right”, respectively.

Embodiment

(1) Overall Configuration of Electrochemical Module M

The following is a description of the overall configuration of the electrochemical module M according to an embodiment. As shown in FIG. 1, the electrochemical module M includes an electrochemical element stack (stack) S, and a container (a housing, a first clamping portion, a second clamping portion) 200 that has a substantially rectangular parallelepiped shape and is internally provided with the electrochemical element stack S. An electrochemical element A (FIG. 4) is an element for generating power and is formed in a plate shape extending from the front side to the back side in the cross-sectional view shown in FIG. 1. The electrochemical element stack S has a configuration in which a plurality of plate-like electrochemical elements A are stacked in a vertical stacking direction in the cross-sectional view shown in FIG. 1. In the description of this embodiment, a SOFC (Solid Oxide Fuel Cell) is used as an example of the electrochemical element A.

The electrochemical module M also includes a first gas supply portion (flowing pipe) 61 for supplying first gas to the electrochemical element stack S from the outside of the container 200, and a first gas discharge portion (flowing pipe) 62 for discharging the first gas used in a reaction in the electrochemical element stack S. The first gas supply portion (flowing pipe) 61 and the first gas discharge portion (flowing pipe) 62 are connected to the top flat face (second flat face) of the electrochemical element stack S.

Moreover, pressing mechanisms 400, which will be described later, are provided corresponding to the first gas supply portion 61 and the first gas discharge portion 62. The pressing mechanisms 400 can press the first gas supply portion 61 and a plurality of first annular sealing portions 42, and the first gas discharge portion 62 and a plurality of second annular sealing portions 52 toward the electrochemical element stack S.

As shown in FIGS. 1 to 3, the container 200 is provided with a second gas supply portion 71 for supplying second gas to the electrochemical element stack S from the outside of the container 200. The second gas used in a reaction in the electrochemical element stack S is discharged from a second gas discharge portion 72 provided in the container 200 to the outside.

Here, for example, the first gas is reducing component gas such as fuel gas, and the second gas is oxidative component gas such as air.

The electrochemical module M includes perforated plate members 240 on the two side faces of the electrochemical element stack S in the cross-sectional view shown in FIG. 1. The perforated plate members 240 are plate-like members that correspond to the two side faces of the electrochemical element stack S and extend in the direction in which the electrochemical elements A are stacked, and are preferably made of an insulating material such as mica for the purpose of preventing electric short (short circuit) in the electrochemical module M. The perforated plate members 240 are each provided with a plurality of holes 240 a that pass through the perforated plate member 240 in the plane direction of the electrochemical element stack S.

Accordingly, the electrochemical element stack S is configured such that fuel gas is supplied from the first gas supply portion 61, air is supplied from the second gas supply portion 71 through the holes 240 a of the perforated plate member 240, and power is generated through an electrochemical reaction between the fuel gas and oxygen in the air. The fuel gas used in the electrochemical reaction is discharged from the first gas discharge portion 62 to the outside. The air used in the electrochemical reaction is introduced into the second gas discharge portion 72 through the holes 240 a of the perforated plate member 240, and is discharged from the second gas discharge portion 72 to the outside.

It should be noted that, here, the perforated plate members 240 are provided adjacent to the two side faces of the electrochemical element stack S, but this configuration is not essential, and configurations are also possible in which only one of them is provided, or in which both of them are omitted.

The electrochemical module M includes, on the upside of the electrochemical element stack S, an upper insulator 210T and an upper plate (first clamping portion) 230T, which are arranged in the stated order from the electrochemical element stack S side toward the outside. The electrochemical module M includes, on the underside of the electrochemical element stack S, a lower insulator 210B, a lower plate-like member (first plate-like member) 220B, and a lower plate (second clamping portion) 230B, which are arranged in the stated order from the electrochemical element stack S side toward the outside.

The electrochemical element stack S will be described in detail later.

(2) Insulator, Lower Plate-Like Member, Plate, Container, and Pressing Mechanism

The following is a further description of insulators (upper insulator 210T and lower insulator 210B) 210, the lower plate-like member 220B, plates (upper plate 230T and lower plate 230B) 230, the container 200, and the pressing mechanism 400.

(2-1) Upper Insulator

The upper insulator 210T is a plate-like member and is arranged so as to cover the top flat face (second flat face) of the electrochemical element stack S. The upper insulator 210T is made of, for example, hard mica, and electrically insulates the electrochemical element stack S from the outside. The upper insulator 210T is provided with an opening 210Ta through which the first gas supply portion 61 passes.

(2-2) Upper Plate

The upper plate 230T is a plate-like member, is arranged on the top of the upper insulator 210T, and is made of a ceramics-based material such as 99 alumina that has a high flexural strength at a high temperature. The upper plate 230T is provided with openings 230Ta through which the first gas supply portion 61 and the first gas discharge portion 62 pass.

The electrochemical element stack S, a pair of the upper insulator 210T and the lower insulator 210B, and the lower plate-like member 220B are sandwiched between the upper plate 230T and the lower plate 230B with predetermined clamping pressure applied by the container 200. Here, the clamping pressure refers to, for example, pressure per unit area such as 1 mm².

(2-3) Lower Insulator

The lower insulator 210B is arranged so as to cover the bottom flat face (first flat face) of the electrochemical element stack S. The lower insulator 210B has a configuration similar to that of the upper insulator 210T but is not provided with a through hole.

(2-4) Lower Plate-Like Member

The lower plate-like member 220B is arranged on the underside of the lower insulator 210B. Accordingly, the lower plate-like member 220B is provided along the bottom flat face (first flat face) of the electrochemical element stack S, whereas the first gas supply portion (flowing pipe) 61 and the first gas discharge portion (flowing pipe) 62 are connected to the top flat face (second flat face) of the electrochemical element stack S.

The lower plate-like member 220B is an elastic member, and is formed, for example, in a wavelike shape in the cross-sectional view shown in FIG. 1 in this embodiment. The wavelike shape extends along the flat face of the electrochemical element stack S. Accordingly, the lower plate-like member 220B is arranged such that top portions 220Bb of the wavelike shape are in contact with the lower insulator 210B. The lower plate-like member 220B is not provided with a through hole.

The thickness of the lower plate-like member 220B having a wavelike shape is, for example, about 0.1 mm to 1 mm, but is not limited thereto. The amplitude (height) of the wavelike shape is, for example, about 1 mm to 10 mm, but is not limited thereto.

The role of the lower plate-like member 220B will be described later.

(2-5) Lower Plate

The lower plate 230B is arranged on the underside of the lower plate-like member 220B. The lower plate 230B has a configuration similar to that of the upper plate 230T but is not provided with a through hole.

(2-6) Container

As shown in FIGS. 1 to 3, the container 200 that is internally provided with the electrochemical element stack S has a substantially rectangular parallelepiped shape. The container 200 includes an upper cover (first clamping portion) 201 having a box shape whose bottom portion is open, and a lower cover 203 (second clamping portion) whose top portion is open. The area surrounded by the outer edge of the upper cover 201 is larger than the area surrounded by the outer edge of the lower cover 203, and the upper cover 201 and the lower cover 203 are assembled such that the upper cover 201 covers the outer edge of the lower cover 203. The upper cover 201 and the lower cover 203 are fastened to each other through welding, bonding, fitting, or the like of the contact faces of the upper cover 201 and the lower cover 203. Thus, a space having a rectangular parallelepiped shape is formed inside the upper cover 201 and the lower cover 203.

In this embodiment, as shown in FIG. 1, the depth of the lower cover 203 in the vertical direction (direction in which the electrochemical elements A are stacked) is larger than the depth of the upper cover 201. However, it is sufficient that the upper cover 201 and the lower cover 203 can form a space therein when integrated, and the relationship between their depths is not limited to the above-mentioned relationship. For example, the depth of the upper cover 201 may be larger than that of the lower cover 203.

As shown in FIGS. 1 to 3, at the center in the vertical direction of the container 200, a second gas supply portion 71 and a second gas discharge portion 72 are respectively formed in the two side walls of the lower cover 203 that are opposed to each other.

It should be noted that, here, the lower cover 203 is provided with the second gas supply portion 71 and the second gas discharge portion 72. However, the positions at which the second gas supply portion 71 and the second gas discharge portion 72 are formed are not limited to the above-mentioned positions, and they may be formed at any positions on the container 200. For example, the upper cover 201 may be provided with the second gas supply portion 71 and the second gas discharge portion 72.

As shown in FIGS. 1 and 2, the upper cover 201 includes a flat face portion 201 a. A first end portion 201 c with a predetermined length that forms a side face extends downward in the stacking direction of the electrochemical element stack S from the outermost portion of the flat face portion 201 a. The first end portion 201 c forms an angle of approximately 90° with the flat face portion 201 a in a cross-sectional view, and forms the outer edge of the upper cover 201. A second end portion 201 b with a predetermined length extends downward in the above-mentioned stacking direction from the position located inward of the first end portion 201 c, and forms an angle of approximately 90° with the flat face portion 201 a in a cross-sectional view. The flat face portion 201 a and the second end portion 201 b form an L-shaped corner portion.

Moreover, an opening 201 d that is slightly smaller in size than the area surrounded by the first end portion 201 c forming the outer edge is formed in a portion of the flat face portion 201 a inward of the second end portion 201 b.

Furthermore, the flat face portion 201 a is provided with cylindrical openings corresponding to the first gas supply portion 61 and the first gas discharge portion 62 between the second end portion 201 b and the opening 201 d, and first screw members 401, which will be described later, protrude upward in the above-mentioned stacking direction from these openings.

As shown in FIG. 1, the lower cover 203 includes a flat face portion 203 a. A first end portion 203 b with a predetermined length that forms a side face extends upward in the stacking direction of the electrochemical element stack S from the outermost portion of the flat face portion 203 a. The first end portion 203 b forms an angle of approximately 90° with the flat face portion 203 a in a cross-sectional view, and forms the outer edge of the lower cover 203. The area surrounded by the first end portion 203 b forming the outer edge of the lower cover 203 is slightly smaller than the area surrounded by the first end portion 201 c forming the outer edge of the upper cover 201. In the state in which the upper cover 201 is fitted to the lower cover 203, the first end portion 203 b of the lower cover 203 is in intimate contact with the inner peripheral face of the first end portion 201 c of the upper cover 201.

Moreover, a second end portion 203 c with a predetermined length extends upward in the above-mentioned stacking direction from the position located inward of the first end portion 203 b, and forms an angle of approximately 90° with the flat face portion 201 a in a cross-sectional view. The flat face portion 203 a and the second end portion 203 c form an L-shaped corner portion.

In addition, the first end portion 203 b is provided with third end portions 203 d extending outward in a direction that intersects the stacking direction. The third end portions 203 d form the second gas supply portion 71 and the second gas discharge portion 72.

As shown in FIG. 1, the upper ends of the two perforated plate members 240, the upper insulator 210T, and the upper plate 230T are fitted onto the L-shaped corner portion formed by the flat face portion 201 a and the second end portion 201 b of the upper cover 201. Specifically, the top face of the outer peripheral end portion of the upper plate 230T extending in the plane direction of the electrochemical element stack S is in contact with the bottom face of the flat face portion 201 a (a portion of the inner face of the L-shaped corner portion) and is supported thereby. The outer face of the upper end portion of each of the perforated plate members 240 extending along the side face of the electrochemical element stack S is in contact with the inner side face of the second end portion 201 b (a portion of the inner face of the L-shaped corner portion) and is supported thereby. The upper insulator 210T is supported by the L-shaped corner portion formed by the flat face portion 201 a and the second end portion 201 b, via the upper plate 230T and the perforated plate members 240.

Similarly, the lower ends of the two perforated plate members 240, the lower insulator 210B, the lower plate-like member 220B, and the lower plate 230B are fitted onto a pair of L-shaped corner portions that are opposed to each other in the plane direction of the lower cover 203.

The top face of the electrochemical element stack S is supported by the upper cover 201 via the upper plate 230T and the upper insulator 210T. The bottom face of the electrochemical element stack S is supported by the lower cover 203 via the lower plate 230B, the lower plate-like member 220B, and the lower insulator 210B.

The upper cover 201 and the lower cover 203 having these configurations are fastened to each other through adhesion, welding, bonding, fitting, or the like of the inner peripheral face of the first end portion 201 c of the upper cover 201 and the first end portion 203 b of the lower cover 203 that is performed in the state in which the electrochemical element stack S, the upper insulator 210T, the lower insulator 210B, the lower plate-like member 220B, the upper plate 230T, the lower plate 230B, and the like are sandwiched between the upper cover 201 and the lower cover 203 from above and below. During this fastening, the upper cover 201 and the lower cover 203 are coupled to each other while applying predetermined clamping pressure to the electrochemical element stack S and the like. That is, in the state in which the upper cover 201 and the lower cover 203 are coupled to each other, predetermined clamping pressure is applied to the electrochemical element stack S, the upper insulator 210T, the lower insulator 210B, the lower plate-like member 220B, the upper plate 230T, and the lower plate 230B.

Furthermore, the pressing mechanisms 400 can press the first gas supply portion 61 and the first gas discharge portion 62 toward the electrochemical element stack S.

Accordingly, as shown in FIG. 4, predetermined clamping pressure is applied to the region in the electrochemical element stack S that extends in the stacking direction and is provided with electrochemical reaction portions 3, due to the upper cover 201 and the lower cover 203 pressing the upper insulator 210T, the lower insulator 210B, the lower plate-like member 220B, the upper plate 230T, the lower plate 230B, and the like. On the other hand, not only the upper cover 201 and the lower cover 203 apply the clamping pressure to the regions in the electrochemical element stack S that extend in the stacking direction and are respectively provided with the first gas supply portion 61 and the first gas discharge portion 62, but also the pressing mechanisms 400 can press these regions.

It should be noted that, as shown in FIG. 3, openings 203 e are formed in the side face of the lower cover 203. Accordingly, portions of the side face of the electrochemical element stack S are exposed from the openings 203 e. Providing the container 200 with the above-described opening 201 d and the openings 203 e makes it possible to reduce the weight of the container 200 and reduce the amount of the material necessary for the container 200. It should be noted that, when electric short (short circuit) may occur due to contact between the side face of the electrochemical element stack S and one or both of the upper cover 201 and the lower cover 203, a side insulator 245 made of a material such as mica is provided between the electrochemical element stack S and the side face of the upper cover 201 or lower cover 203.

(2-7) Pressing Mechanism

The pressing mechanisms 400 are respectively provided corresponding to the first gas supply portion 61 and the first gas discharge portion 62.

First, the first gas supply portion 61 will be described.

As shown in FIGS. 1 and 4, the first gas supply portion 61 is a passage for introducing the first gas into the container 200 from the outside of the container 200 in order to supply the first gas to the electrochemical element stack S. The first gas supply portion 61 includes a cylindrical supply penetrated portion 61 a through which the first gas flows, a supply upper end portion 61 b corresponding to the upper end, and a supply lower end portion 61 c corresponding to the lower end. It should be noted that, below the first gas supply portion 61, the first annular sealing portions 42 (which will be described later) provided in the electrochemical elements A are stacked in the stacking direction as the electrochemical elements A are stacked. In this case, the first gas supply portion 61 is substantially coaxial with the plurality of first annular sealing portions 42 in the stacking direction.

An annular bulging portion a is provided on the top face of the first plate-like body 1 adjacent to the collector 81, which will be described later. The supply lower end portion 61 c of the first gas supply portion 61 is fitted into the inner circumference of the annular bulging portion a and is welded to the top face of the first plate-like body 1. The bulging portion a is constituted by a sealing member such as a packing, for example. Moreover, the bulging portion a located at the position at which the first gas supply portion 61 is welded to the first plate-like body 1, namely the uppermost bulging portion a shown in FIG. 4, is constituted by a collector packing or the like, for example.

It should be noted that a bulging portion a is provided at a position corresponding to the first annular sealing portion 42 on the top face of each first plate-like body 1, and this configuration will be described later.

Next, the pressing mechanism 400 provided corresponding to the first gas supply portion 61 will be described. The pressing mechanism 400 presses the first gas supply portion 61 and the plurality of first annular sealing portions 42 in the stacking direction.

The pressing mechanism 400 includes a first screw member 401 with a predetermined length that extends upward in the stacking direction of the electrochemical element stack S from a portion of the flat face portion 201 a of the upper cover 201 that corresponds to the first gas supply portion 61. The first screw member 401 is a cylindrical member provided with an internal thread portion 401 a on the inner circumferential face.

The pressing mechanism 400 further includes a second screw member 403 that is inserted into a cylindrical portion of the first screw member 401 and screwed thereonto, and a screwing portion 405 for screwing the second screw member 403. An external thread portion 403 a that is screwed onto the internal thread portion 401 a of the first screw member 401 is formed on the outer circumferential face of the second screw member 403.

The second screw member 403 and the screwing portion 405 are each provided with a supply through hole 407 that passes therethrough. The second screw member 403 and the screwing portion 405 correspond to the first gas supply portion 61 such that the supply through holes 407 and the supply penetrated portion 61 a are in communication. Thus, the first gas is supplied to the electrochemical element stack S from the outside through the supply through holes 407 and the supply penetrated portion 61 a.

It is preferable that the pressing mechanism 400 includes an electrical insulating annular sealing portion (sealing portion) 410 between the second screw member 403 and the supply upper end portion 61 b of the first gas supply portion 61. The electrical insulating annular sealing portion 410 suppresses leakage of the first gas between the second screw member 403 and the first gas supply portion 61, and suppresses electric short (short circuit) in the electrochemical element stack S.

When the second screw member 403 is screwed into the first screw member 401, the internal thread portion 401 a and the external thread portion 403 a engage with each other, and the second screw member 403 is thrusted downward in the stacking direction. Thus, the second screw member 403 thrusts the first gas supply portion 61 downward in the stacking direction via the annular sealing portion 410. When the first gas supply portion 61 is thrusted, the thrusting force applied to the first gas supply portion 61 is transmitted to the plurality of first annular sealing portions 42 that are stacked below the first gas supply portion 61.

On the other hand, the lower plate-like member 220B transmits, toward the electrochemical element stack S side, appropriate clamping pressure derived from the elastic force that results from the compressional deformation caused in advance and the elastic force that results from thermal expansion of the lower plate-like member 220B itself.

As shown in FIG. 4, each of the first annular sealing portions 42 is in contact with the first plate-like body 1 and a second plate-like body 2. The pressing mechanism 400 applies a downward thrusting force to the first annular sealing portion 42 in the stacking direction and the lower plate-like member 220B applies an upward thrusting force thereto in the stacking direction, thus making it possible to suppress generation of a gap between the first annular sealing portion 42 and a member that is in contact with the first annular sealing portion 42. Thus, leakage of the first gas through the gap can be suppressed.

It should be noted that, if the second screw member 403 is intimately connected to the supply upper end portion 61 b of the first gas supply portion 61, and thus the first gas does not leak from the connection portion where the second screw member 403 and the supply upper end portion 61 b are connected, the annular sealing portion 410 need not be necessarily provided. Alternatively, if electric short (short circuit) of the electrochemical module does not occur at this connection portion, the annular sealing portion 410 need not be necessarily provided.

Next, the first gas discharge portion 62 and the pressing mechanism 400 corresponding to the first gas discharge portion 62 will be described.

The first gas discharge portion 62 is a passage for discharging the first gas to the outside, and has a configuration similar to that of the first gas supply portion 61. Accordingly, the first gas discharge portion 62 and the pressing mechanism 400 will be briefly described hereinafter. The first gas discharge portion 62 includes a cylindrical discharge penetrated portion 62 a through which the first gas flows, a discharge upper end portion 62 b corresponding to the upper end, and a discharge lower end portion 62 c corresponding to the lower end.

The pressing mechanism 400 includes the first screw member 401, the second screw member 403, the screwing portion 405, and the annular sealing portion 410.

When the second screw member 403 is screwed into the first screw member 401, the second screw member 403 is thrusted downward in the stacking direction. Thus, the second screw member 403 thrusts the first gas discharge portion 62 downward in the stacking direction via the annular sealing portion 410. When the first gas discharge portion 62 is thrusted, the thrusting force applied to the first gas discharge portion 62 is transmitted to the plurality of second annular sealing portions 52 that are stacked below the first gas discharge portion 62. On the other hand, independent of a downward pressing force in the stacking direction applied by the pressing mechanism 400, the lower plate-like member 220B transmits an upward pressing force toward the electrochemical element stack S side in the stacking direction. That is, the lower plate-like member 220B transmits, upward in the stacking direction toward the electrochemical element stack S side, appropriate clamping pressure derived from the elastic force that results from the compressional deformation caused in advance and the elastic force that results from thermal expansion of the lower plate-like member 220B itself.

As shown in FIG. 4, each of the second annular sealing portions 52 is in contact with the first plate-like body 1 and the second plate-like body 2. The pressing mechanism 400 applies a downward thrusting force to the second annular sealing portion 52 in the stacking direction and the lower plate-like member 220B applies an upward thrusting force thereto in the stacking direction, thus making it possible to suppress generation of a gap between the second annular sealing portion 52 and a member that is in contact with the second annular sealing portion 52. Thus, leakage of the first gas through the gap can be suppressed.

(3) Configurations and Functions of Lower Plate-Like Member and Related Members

Next, the configurations and functions of the lower plate-like member 220B and related members will be further described.

As described above, in the state in which the upper cover 201 and the lower cover 203 are coupled to each other, the electrochemical element stack S, the upper insulator 210T, and the lower insulator 210B are clamped between the upper plate 230T and the lower plate 230B while predetermined clamping pressure is applied to the electrochemical element stack S, the upper insulator 210T, and the lower insulator 210B via the lower plate-like member 220B.

(3-1) Configurations of Lower Portion and Related Members

In this embodiment, the lower plate-like member 220B is constituted by a thermally expandable member that thermally expands. It is preferable that the lower plate-like member 220B has a thermal expansion rate larger than the thermal expansion rates of members included in the electrochemical element stack S, the container 200, and the like. An example of the material of such a lower plate-like member 220B is austenite-based stainless steel.

Austenite-based stainless steel has a relatively large thermal expansion rate. For example, aluminum has a thermal expansion rate of about 23.8×10⁻⁶1° C., and austenite-based stainless steel has a thermal expansion rate as large as the thermal expansion rates of aluminum and the like. Regarding the thermal expansion rate of austenite-based stainless steel, SUS303 and SUS304 have a thermal expansion rate of about 17.3×10⁻⁶/° C., and SUS316 has a thermal expansion rate of about 16×10⁻⁶/° C. However, the material of the lower plate-like member 220B is not limited thereto, and it is preferable to select a member that has a thermal expansion rate larger than those of the container 200 and the like and has excellent corrosion resistance.

It is preferable that the container 200 has a thermal expansion rate smaller than the thermal expansion rate of the lower plate-like member 220B. The container 200 is arranged adjacent to the lower plate-like member 220B via the plate 230. The lower cover 203 and the upper cover 201 of the container 200 are linked to each other and thus apply clamping pressure to the electrochemical element stack S via the lower plate-like member 220B. Examples of the material of such a container 200 include ferrite-based stainless steel, martensite-based stainless steel, and complexes between ceramics and the above-mentioned stainless steel. These materials have thermal expansion rates smaller than that of austenite-based stainless steel. Regarding the thermal expansion rate of ferrite-based stainless steel, SUS430 has a thermal expansion rate of about 11×10⁻⁶/° C. Regarding the thermal expansion rate of martensite-based stainless steel, SUS403 and SUS420J1 have a thermal expansion rate of about 10.4×10⁻⁶/° C., and SUS410 and SUS440C have a thermal expansion rate of about 10.1×10⁻⁶/° C. However, the container 200 is not limited thereto, and it is preferable to select a material that has a thermal expansion rate smaller than that of the lower plate-like member 220B and has excellent corrosion resistance.

It is preferable that the material of the electrochemical element stack S is similar to the material of the container 200. In other words, it is preferable that a material of the electrochemical element stack S has a thermal expansion rate as large as that of the material of the container 200. In this case, the substrates of the electrochemical element stack S and the container 200 thermally expand to the same degree, for example, at the time of power generation when the electrochemical elements A become hot. Accordingly, it is possible, for example, to reduce a difference in thermal expansion between the substrates of the electrochemical elements A and the container 200 and suppress damage or the like on the substrates.

(3-2) Configurations of Pressing Mechanism and Related Members

The thermal expansion rates of the first screw member 401 and the second screw member 403 included in the pressing mechanism 400 are smaller than or equal to the thermal expansion rates of the first gas supply portion 61 and the first gas discharge portion 62. The pressing mechanism 400 can be made of a metal such as SUS316, for example. Also, the first gas supply portion 61 can be made of a metal such as SUS316, for example.

Since the thermal expansion rate of the pressing mechanism 400 is smaller than or equal to the thermal expansion rates of the first gas supply portion 61 and the first gas discharge portion 62, it is possible to suppress transmission loss of pressing force applied to the first annular sealing portion 42 and the second annular sealing portion 52 from the pressing mechanisms 400 via the first gas supply portion 61 and the first gas discharge portion 62.

For example, a case is assumed where the thermal expansion rate of the pressing mechanism 400 is larger than the thermal expansion rates of the first gas supply portion 61 and the first gas discharge portion 62. In some cases, the pressing mechanism 400 thermally expands in a direction different from the direction in which the first gas supply portion 61, the first gas discharge portion 62, the first annular sealing portion 42, and the second annular sealing portion 52 are to be pressed by the pressing mechanism 400, that is, the pressing mechanism 400 thermally expands toward a side opposite to the side on which the electrochemical element stack S is located. Furthermore, in some cases, the first gas supply portion 61 and the first gas discharge portion 62 cannot follow the expansion of the pressing mechanism 400. Accordingly, a clearance between the pressing mechanism 400 and the first gas supply portion 61, and a clearance between the pressing mechanism 400 and the first gas discharge portion 62 increase in size, and thus a pressing force cannot be sufficiently transmitted to the first annular sealing portion 42 and the second annular sealing portion 52 from the pressing mechanisms 400 via the first gas supply portion 61 and the first gas discharge portion 62.

(3-3) Method for Assembling Electrochemical Module M and Compressional Deformation

(a) Method for Assembling Electrochemical Module M and Compressional Deformation

Next, a method for assembling the above-mentioned electrochemical module M will be described.

The electrochemical element stack S is prepared by stacking a plurality of electrochemical elements A. The configuration of the electrochemical element stack S, and a method for manufacturing the electrochemical element stack S will be described later.

The container 200 for housing the electrochemical element stack S is also prepared. The container 200 can be manufactured using, for example, a lost-wax casting method, but the manufacturing method is not limited thereto. When the lost-wax casting method is used, a model corresponding to the external shape of the container 200 is manufactured using, for example, a thermoplastic substance such as beeswax or pine resin. Afire-resistant material made of silica sand, lime powder, and the like is used to cover this model. Thereafter, the model covered by the fire-resistant material is heated, and thus the model made of the thermoplastic substance is melted and removed. Accordingly, a cavity corresponding to the model having the shape of the container 200 is formed inside the fire-resistant material. The material of the container 200 is injected into this cavity and solidified, and then the fire-resistant substance is removed. Accordingly, the container 200 that includes the upper cover 201 and the lower cover 203 is manufactured using the lost-wax casting method. It should be noted that the upper cover 201 and the lower cover 203 may be separately manufactured.

Next, for example, the two perforated plate members 240 are arranged on the two side faces of the electrochemical element stack S, and the upper plate 230T, the upper insulator 210T, the electrochemical element stack S, the lower insulator 210B, the lower plate-like member 220B, and the lower plate 230B are arranged in the stated order from the upper side to the lower side in the stacking direction, and these members are housed in the lower cover 203 while this state is maintained. The lower cover 203 is covered by the upper cover 201, positional adjustment is performed such that predetermined clamping pressure is applied to the electrochemical element stack S, and then the lower cover 203 and the upper cover 201 are linked to each other through welding or the like. The electrochemical module M is thus assembled.

When the container 200 is manufactured using the lost-wax casting method as mentioned above, the cost can be reduced due to a reduction in thickness, manufacturing accuracy, and mass production.

In this embodiment, forming the box-shaped container 200 makes it possible to provide a space for a manifold for supplying air from the second gas supply portion 71 to the electrochemical element stack S.

Moreover, if there is a possibility that the first gas leaks through a gap between the first annular sealing portion 42 and a member that is in contact therewith and a gap between the second annular sealing portion 52 and a member that is in contact therewith, a pressing force is applied to the first annular sealing portion 42 and the second annular sealing portion 52 from the pressing mechanisms 400. That is, the second screw member 403 is screwed into the first screw member 401, and thus the second screw member 403 is thrusted downward in the stacking direction.

(b) Compressional Deformation of Lower Plate-Like Member 220B during Assembly

During the above-mentioned assembly of the electrochemical module M, predetermined clamping pressure is applied to the electrochemical element stack S when the lower cover 203 and the upper cover 201 are linked to each other. This clamping pressure is applied by causing predetermined compressional deformation L of the lower plate-like member 220B.

The following is a description of the compressional deformation L.

In the following description, it is supposed that the container 200 is made of a predetermined material A, the main portions of the electrochemical element stack S, such as the substrates, are made of a predetermined material B, and the lower plate-like member 220B is made of a predetermined material C. The material C has a thermal expansion rate larger than the thermal expansion rates of the materials A and B.

Here, the spring constant of the lower plate-like member 220B at room temperature (20° C.) is taken as K20.

The spring constant K20 is calculated using, for example, the thickness, the amplitude (height) of the wavelike shape, the pitch of the wave and the like of the lower plate-like member 220B.

In addition, the spring constant at a temperature (e.g., 700° C.) during power generation by the electrochemical element A is taken as K700. It should be noted that K700 is, for example, about 75% of K20.

Here, clamping pressure per unit area required for the electrochemical element stack S during power generation (e.g., at 700° C.) is taken as P. Here, P is, for example, about 1 to 3 kgf/cm², but is not limited thereto. When the area of the electrochemical element stack S to which pressure needs to be applied is taken as SB, an applied force F is represented as follows: F=P×SB.

When the temperature rises from room temperature (20° C.) to a high temperature (e.g., 700° C.) during power generation, the thermal expansion lengths of the container 200, the electrochemical element stack S, and the lower plate-like member 220B in the application direction (here, a direction in which the electrochemical elements A are stacked) are taken as LA, LB, and LC, respectively.

A difference ΔG in the thermal expansion length between the container 200 and the electrochemical element stack S is expressed as follows: ΔG=LA−LB. Here, a difference in the thermal expansion length between the container 200, and the electrochemical element stack S and the lower plate-like member 220B may be calculated as the difference ΔG in the thermal expansion length. In this case, ΔG is expressed as follows: ΔG=LA−(LB+LC). In the following description, the expression ΔG=LA−LB is used supposing that the lower plate-like member 220B does not thermally expand, so that appropriate clamping pressure can be more reliably applied due to the compressional deformation L of the lower plate-like member 220B during assembly even after the container 200 and the like thermally expand.

Here, the compressional deformation L of the lower plate-like member 220B at room temperature (20° C.) to keep the clamping pressure P per unit area at a high temperature (e.g., 700° C.) during power generation is calculated using the following expression.

L=P×SB/(K700)+ΔG

As described above, after the electrochemical element stack S, the lower plate-like member 220B, and the like are housed in the container 200, the linkage distance between the lower cover 203 and the upper cover 201, and the like are adjusted such that the compressional deformation L calculated as mentioned above is caused in the lower plate-like member 220B, and then the lower cover 203 and the upper cover 201 are sealed through welding or the like. This makes it possible to apply predetermined clamping pressure to the electrochemical element stack S.

(3-4) Functions

(a) Functions of Lower Plate-Like Member 220B

As mentioned above, the lower plate-like member 220B constituted by a thermally expandable member is arranged on the bottom flat face of the electrochemical element stack S, and elastically supports the electrochemical element stack S due to the upper and lower plates 230 applying predetermined clamping pressure thereto.

Here, for example, at least one of the electrochemical element stack S, the container 200, and the like expands when shifting from a low-temperature state (e.g., about 20° C. in room-temperature atmosphere) in which the electrochemical elements A do not generate power to a high-temperature state (e.g., about 650° C. to about 950° C.) in which the electrochemical elements A generate power. At this time, if a difference in thermal expansion between the electrochemical element stack S and the container 200 occurs, a clearance between the electrochemical element stack S and the container 200 changes between when power is generated (high-temperature state) and when power is not generated (low-temperature state).

With the above-mentioned configuration, the lower plate-like member 220B is a thermally expandable member, and therefore, the lower plate-like member 220B also thermally expands due to high temperature of the electrochemical elements A during power generation. Accordingly, even when a clearance between the electrochemical element stack S and the container 200 changes due to thermal expansion, the lower plate-like member 220B applies, to the electrochemical element stack S, appropriate upward clamping pressure in the stacking direction with the lower plate 230B being used as a pressing face by utilizing the elastic force that results from thermal expansion of the lower plate-like member 220B itself and the elastic force that results from the compressional deformation L caused in advance.

That is, the change of a clearance between the electrochemical element stack S and the container 200 due to thermal expansion can be compensated with the change of the lower plate-like member 220B due to thermal expansion. Accordingly, appropriate upward clamping pressure is applied to the electrochemical element stack S in the stacking direction even after the above-described clearance has changed. For example, the lower plate-like member 220B thermally expands and compensates for a clearance between the electrochemical element stack S and the container 200 that has increased in size due to thermal expansion, and thus appropriate clamping pressure is applied to the electrochemical element stack S.

Since the lower plate-like member 220B is arranged along the bottom flat face of the electrochemical element stack S and the flat face of the lower plate 230B, the lower plate-like member 220B substantially uniformly applies appropriate clamping pressure along the bottom flat face of the electrochemical element stack S even after the above-described clearance has changed. Accordingly, in the electrochemical module M, it is possible to suppress a decrease in contact areas between the electrochemical elements A and to reduce internal resistance. In addition, since the electrochemical elements A can be brought into appropriate contact with each other to maintain gastightness, it is possible to suppress leakage of fuel gas and the like to the outside of the electrochemical elements A and a decrease in the ability to seal in reaction gas.

As described above, a small-size, light-weight, and low-cost electrochemical module in which the electrochemical element stack S and the like can be clamped appropriately even when the electrochemical element stack S and the like expand can be achieved.

In particular, in the above-mentioned embodiment, the lower plate-like member 220B has a thermal expansion rate larger than the thermal expansion rates of the members included in the container 200. To achieve this relationship, for example, austenite-based stainless steel is employed as the material of the lower plate-like member 220B, and ferrite-based stainless steel, martensite-based stainless steel, a complex between the above-mentioned stainless steel and ceramics, or the like is employed as the material of the container 200. In addition, a stainless steel material that is of the same type as the material of the container 200 is employed as the base material of the electrochemical element stack S.

Here, as described above, when the electrochemical element stack S shifts from a low-temperature state in which power is not generated to a high-temperature state in which power is generated, at least one of the electrochemical element stack S and the container 200 thermally expands, and a difference in the thermal expansion amount between the electrochemical element stack S and the container 200 occurs. As a result, a clearance between the electrochemical element stack S and the container 200 increases in size in the high-temperature state compared with the low-temperature state. For example, when the thermal expansion amount of the container 200 is relatively large, the clearance between the electrochemical element stack S and the container 200 further increases in size.

In this embodiment, as described above, the lower plate-like member 220B has a thermal expansion rate larger than the thermal expansion rates of the members included in the container 200. Accordingly, a clearance between the electrochemical element stack S and the container 200 that has increased in size particularly due to expansion of the container 200 can be compensated with thermal expansion of the lower plate-like member 220B. That is, even when the clearance between the electrochemical element stack S and the container 200 changes due to thermal expansion in a direction in which the clearance significantly increases in size, the above-described clearance can be compensated with the lower plate-like member 220B that thermally expands more greatly. Accordingly, even after this clearance has changed, appropriate upward clamping pressure can be substantially uniformly applied in the stacking direction over the flat face of the electrochemical element stack S by utilizing the elastic force that results from the compressional deformation caused in the lower plate-like member 220B in advance and the elastic force that results from thermal expansion of the lower plate-like member 220B itself.

It should be noted that, when the container 200 has a relatively small thermal expansion rate, the thermal expansion amount of the container 200 can be suppressed to a small value, for example, in the case where the container 200 becomes hot during power generation. Thus, an increase in the size of the clearance between the electrochemical element stack S and the container 200 due to thermal expansion can be suppressed. Accordingly, even when the lower plate-like member 220B has a relatively small thermal expansion rate, appropriate clamping pressure can be substantially uniformly applied along the flat face of the electrochemical element stack S after the above-described clearance has changed.

In addition, when the thermal expansion amount of the container 200 is small, the locational shifting, breakage, and the like of the substrates, etc. of the electrochemical elements A caused by expansion of the container 200 can be suppressed.

In the above-mentioned embodiment, the lower plate-like member 220B is formed in a wavelike shape. Accordingly, the top portions of the wavelike shape of the lower plate-like member 220B are in contact alternately with the flat face of the lower plate 230B and the bottom flat face of the electrochemical element stack S via the lower insulator 210B, at a plurality of positions that are scattered.

When the clearance between the electrochemical element stack S and the container 200 changes due to expansion of at least one of the electrochemical element stack S and the container 200, a pressing force applied to the lower plate-like member 220B also changes due to the change of the clearance. The pressing force, which has changed, is elastically received via the lower plate-like member 220B in a state of being substantially uniformly scattered on the substantially entire bottom flat face of the electrochemical element stack S and the substantially entire flat face of the lower plate 230B. This is because the lower plate-like member 220B is in contact with the bottom flat face of the electrochemical element stack S and the flat face of the lower plate 230B at a plurality of positions that are scattered as described above. Furthermore, when the lower plate-like member 220B thermally changes, the change of the clearance between the electrochemical element stack S and the container 200 is received by the thermal expansion and the elasticity of the lower plate-like member 220B itself at the above-described positions.

Accordingly, even when the clearance between the electrochemical element stack S and the container 200 changes due to expansion of the electrochemical element stack S and the like, appropriate clamping pressure in the stacking direction can be substantially uniformly applied along the flat face of the electrochemical element stack S due to the lower plate-like member 220B. This makes it possible to suppress an increase in internal resistance and a decrease in the ability to seal in reaction gas in the electrochemical module M and to reduce the size and weight of the electrochemical module M.

In this embodiment, the electrochemical element stack S includes SOFCs, which are electrochemical elements. The temperature of the SOFC is as high as, for example, about 650° C. to about 950° C. during power generation. Therefore, the expansion amounts of the electrochemical element stack S, the container 200, and the like increase due to these members shifting from the low-temperature state (e.g., about 20° C. in room-temperature atmosphere) in which power is not generated to the high-temperature state (e.g., about 650° C. to about 950° C.) in which power is generated. In this embodiment, the lower plate-like member 220B can apply appropriate clamping pressure to the electrochemical element stack S with the lower plate 230B being used as a pressing face by utilizing a change of the elastic force resulting from thermal expansion of the lower plate-like member 220B itself. Accordingly, even when SOFCs that generate power in a high-temperature range are used, this embodiment can be employed to apply appropriate clamping pressure to the electrochemical element stack S.

A reduction in size of the electrochemical module M will be further described. For example, in a case of a configuration in which the peripheral portions of two thick clamping plates are fastened to apply clamping pressure to the electrochemical element stack S, large-size tightening bolts provided with a spring need to be provided, as tightening members, on the outside of the electrochemical module M. However, with the above-mentioned embodiment, it is sufficient that the lower plate-like member 220B is arranged inside the electrochemical module M, and thus the size of the electrochemical module M can be reduced.

In a case where protruding objects such as large-size tightening bolts are arranged on the outside of the electrochemical module M, heat is likely to be dissipated through such protruding objects of the electrochemical module M during power generation. Since the lower plate-like member 220B of this embodiment is arranged inside the electrochemical module M, heat dissipation faces can be reduced, thus making it possible to improve the power generation efficiency of the electrochemical module M.

In this embodiment, the clamping pressure is adjusted by the lower plate-like member 220B, and therefore, compared with the case where the clamping pressure applied to the electrochemical element stack S is adjusted using a plurality of large-size tightening bolts or the like, time required to adjust the clamping pressure can be significantly reduced. For example, in a case where the electrochemical element stack S is clamped using a plurality of large-size tightening bolts, it is necessary to adjust the pressure while controlling the torque of the bolts. However, when the lower plate-like member 220B of this embodiment is used, the lower plate-like member 220B substantially uniformly applies clamping pressure to the flat face of the electrochemical element stack S, and therefore, complex torque control as described above is not needed.

(b) Functions of Pressing Mechanism

As described above, the first gas flows through a plurality of gas flowing members such as the first gas supply portion 61, the first annular sealing portion 42, the first gas discharge portion 62, and the second annular sealing portion 52. In particular, if a pressing force applied to the first annular sealing portion 42 and the second annular sealing portion 52 is insufficient, the first gas will leak through gaps generated in contact portions where these members and other members are in contact. For example, the plurality of electrochemical elements A are stacked in the stacking direction and pressed with predetermined clamping pressure, but a pressing force required for the first annular sealing portion 42 and the second annular sealing portion 52 may be larger than a pressing force applied to the electrochemical reaction portions 3.

More specifically, the electrochemical reaction portions 3 each include an electrode layer 31, an electrolyte layer 32, and a counter electrode layer 33, and in the electrochemical reaction portions 3, an electrochemical reaction occurs in which the first gas supplied to an internal passage A1, which will be described later, formed by the first plate-like body 1 and the second plate-like body 2, and the second gas (that is one of reducing component gas and oxidative component gas and different from the first gas) separately supplied to a flowing portion A2, which will be described later, located on a side opposed to the internal passage A1 are used. Through the first annular sealing portions 42 and the second annular sealing portions 52, the first gas is supplied to the internal passage A1, and the first gas is discharged from the internal passage A1. The electrochemical element stack S is formed by stacking the electrochemical elements A that each include the above-described electrochemical reaction portion 3, first annular sealing portion 42, second annular sealing portion 52, and the like, and pressing these members with predetermined clamping pressure.

In this case, due to a difference in the configuration, a pressing force applied to the region on which the plurality of electrochemical reaction portions 3 are present and a pressing force applied to the regions on which the first annular sealing portions 42 and the second annular sealing portions 52 are present may be different from each other in the electrochemical element stack S. A pressing force required for the regions on which the first annular sealing portions 42 and the second annular sealing portions 52 are present may be larger than a pressing force applied to the region on which the plurality of electrochemical reaction portions 3 are present. In this case, if no more than pressing force required for the electrochemical reaction portions 3 is applied to the electrochemical element stack S, the first annular sealing portion 42 and the second annular sealing portion 52 will not be pressed with a required pressing force. As a result, a gap will be generated in a contact portion where the first annular sealing portion and another member are in contact, and the first gas will leak through the gap.

With the above-mentioned configuration, in the electrochemical module M, the regions on which the first annular sealing portions 42 and the second annular sealing portions 52 are present are pressed upward from the lower side in the stacking direction by the elastic lower plate-like member 220B on the bottom flat face side of the electrochemical element stack S. On the other hand, the regions on which the first annular sealing portions 42 and the second annular sealing portions 52 are present are pressed downward in the stacking direction by the pressing mechanisms 400 on the top flat face side of the electrochemical element stack S. Accordingly, the plurality of first annular sealing portions 42 and the plurality of second annular sealing portions 52 are pressed in the stacking direction from both of the bottom flat face side and the top flat face side of the electrochemical element stack S. Thus, leakage of the first gas through a gap between the first annular sealing portion 42 and another member and a gap between the second annular sealing portion 52 and another member can be suppressed. Moreover, since the plurality of first annular sealing portions 42 and the plurality of second annular sealing portions 52 can be pressed independently of the plurality of electrochemical reaction portions 3, an appropriate pressing force capable of suppressing leakage of the first gas through the gaps can be applied to the first annular sealing portions 42 and the second annular sealing portions 52.

Moreover, the electrochemical element stack S is pressed by the lower plate-like member 220B toward the piping including the first gas supply portion 61, the first gas discharge portion 62, and the like to which the first annular sealing portion 42 and the second annular sealing portion 52 are coupled. Accordingly, the connection positions where the first annular sealing portion 42 and the second annular sealing portion 52 are connected to the piping can be substantially fixed. Therefore, the first annular sealing portion 42 and the second annular sealing portion 52 can be fixed to the piping through welding or the like. Accordingly, there is no need to use flexible piping in consideration of a shift of the connection positions where the first annular sealing portion 42 and the second annular sealing portion 52 are connected to the piping, and thus a durable steel pipe can be used for the piping.

(4) Specific Configuration of Electrochemical Module M

Next, the specific configuration of the electrochemical module M will be described with reference to FIGS. 1 and 4. Details of the electrochemical element stack S shown in FIG. 1 is shown in FIG. 4.

As shown in FIGS. 1 and 4, the electrochemical module M includes: the container 200 (the upper cover 201 and the lower cover 203) that is internally provided with the electrochemical element stack S; the first gas supply portion 61 for supplying first gas from the outside of the container 200 to the internal passage A1 via a supply passage 4; the first gas discharge portion 62 for discharging the first gas used in a reaction; the second gas supply portion 71 for supplying second gas from the outside of the container 200 to flowing portions A2; the second gas discharge portion 72 for discharging the second gas used in a reaction; and an output portion 8 to which output generated by an electrochemical reaction in the electrochemical reaction portion 3 is provided,

wherein a distribution chamber 9 for distributing and supplying the second gas supplied from the second gas supply portion 71, to the flowing portions A2 is provided inside the container 200.

The distribution chamber 9 is a space located on a side for supplying second gas to the electrochemical element stack S with respect to the electrochemical element stack S, and

openings are formed on the space side and the flowing portions A2 are in communication with the space therethrough.

In a state of being held between two collectors 81 and 82, the electrochemical element stack S is provided inside the container 200. The output portion 8 extends from the collectors 81 and 82 and is connected to a power supply target provided outside the container 200 so as to freely supply power thereto. Furthermore, the electrochemical element stack S is housed in the container 200 such that at least one of the collectors 81 and 82 is electrically insulated from the container 200 and the container 200 is hermetically sealed against the first gas.

Accordingly, in the electrochemical module M, the fuel gas is supplied from the first gas supply portion 61 and air is supplied from the second gas supply portion 71, so that the fuel gas enters as indicated by dashed arrows and air enters as indicated by solid arrows as shown in FIGS. 1 and 4.

In this embodiment, the first gas supply portion 61 passes through the through hole 81 a of the collector 81, and is positioned by the annular bulging portion a on the top face of the first plate-like body 1 adjacent to the collector 81. The supply upper end portion 61 b of the first gas supply portion 61 is coupled to the first plate-like body 1 through welding or the like. Similarly, the first gas discharge portion 62 passes through the through hole 81 a of the collector 81 and is positioned by the annular bulging portion a on the top face of the first plate-like body 1 adjacent to the collector 81, and the discharge upper end portion 62 b is coupled to the first plate-like body 1 through welding or the like.

The fuel gas supplied from the first gas supply portion 61 is introduced into the supply passage 4 through the first penetrated portion 41 of the topmost electrochemical element A of the electrochemical element stack S, and flows from the supply passage 4 partitioned by the first annular sealing portions 42 into the internal passage A1 in all of the electrochemical elements A. Moreover, the air supplied from the second gas supply portion 71 temporarily flows into the distribution chamber 9, and then flows into the flowing portions A2 formed between the electrochemical elements A.

Incidentally, when the second plate-like body 2 (a portion of a plate-like support 10) is considered as a base, the internal passage A1 is formed between the first plate-like body 1 (a portion of the plate-like support 10) and the second plate-like body 2 at a position at which a portion of the second plate-like body 2 with a wavelike plate-like shape bulges from the first plate-like body 1, and such a portion comes into contact with the electrochemical reaction portion 3 of the adjacent electrochemical element A and can be electrically connected thereto. On the other hand, a portion of the second plate-like body 2 with a wavelike plate-like shape that is in contact with the first plate-like body 1 is electrically connected to the first plate-like body 1, and the flowing portion A2 is formed between the second plate-like body 2 and the electrochemical reaction portion 3 of the adjacent electrochemical element A.

A portion of FIG. 18 shows a cross section of an electrochemical element A including the internal passage A1 and a cross section of an electrochemical element A including the flowing portion A2 that are aligned for the sake of convenience. The fuel gas supplied from the first gas supply portion 61 reaches a distribution portion A12 (see FIGS. 9, 12, and 13), flows and spreads in the width direction of one end portion via the distribution portion A12, and reaches auxiliary passages A11 of the internal passage A1 (see FIGS. 9, 11, and 13). In this case, the first gas (fuel gas) can be equally distributed from the distribution portion A12 to the auxiliary passages A11, thus making it possible to allow the electrochemical elements to equally generate electrochemical output.

Then, the fuel gas that has entered the internal passage A1 can enter the electrode layers 31 and the electrolyte layers 32 via a gas-permeable portion 1A. Moreover, the fuel gas further flows in the internal passage A1 together with the fuel gas used in an electrochemical reaction to a discharge passage 5 formed by the second annular sealing portions 52 via confluence portions A13 and the second penetrated portion 51, and is discharged from the first gas discharge portion 62 to the outside of the container 200, together with the fuel gas that was used in an electrochemical reaction and flows from other electrochemical elements A.

On the other hand, the air supplied from the second gas supply portion 71 enters the flowing portions A2 via the distribution chamber 9, and then can enter the counter electrode layers 33 and the electrolyte layers 32. Moreover, the air further flows in the flowing portions A2 along the electrochemical reaction portions 3 together with air used in an electrochemical reaction, and is discharged from the second gas discharge portion 72 to the outside of the container 200.

With this configuration, the electrochemical elements A are connected in series between the collectors 81 and 82 due to the contact between the second plate-like body 2 and the electrochemical reaction portion 3 of the adjacent electrochemical elements A, and thus power generated following the fuel gas flow and the air flow in the electrochemical reaction portions 3 is extracted from the output portion 8 as composite output.

The configuration of the electrochemical element stack S will be described later in detail.

(5) Modified Examples of Lower Plate-Like Member 220B

(a) In the description above, the lower plate-like member 220B is a thermally expandable member that thermally expands. However, the lower plate-like member 220B is not limited to a thermally expandable member as long as a member that can substantially uniformly apply clamping pressure to the flat face of the electrochemical element stack S when the electrochemical element stack S, the container 200, and the like expand and contract, for example, is used. For example, the lower plate-like member 220B may be a member that has a small thermal expansion rate but has a certain level of elasticity.

The elastic lower plate-like member 220B is arranged on the bottom flat face of the electrochemical element stack S and extends along this flat face. The lower plate-like member 220B elastically supports the electrochemical element stack S due to the container 200 applying predetermined clamping pressure thereto via the lower plate 230B.

When at least one of the electrochemical element stack S and the container 200 expands, a clearance between the electrochemical element stack S and the container 200 may change between before and after expansion of the electrochemical element stack S and the like. The lower plate-like member 220B has elasticity, and therefore, the electrochemical element stack S is elastically clamped in the container 200 due to the elastic force of the lower plate-like member 220B even if the clearance between the electrochemical element stack S and the container 200 changes. That is, clamping pressure is applied to the lower plate-like member 220B from the container 200, and thus the electrochemical element stack S is elastically clamped between the two plates 230.

More specifically, when a clearance between the electrochemical element stack S and the container 200 changes due to expansion of at least one of the electrochemical element stack S and the container 200, a pressing force applied to the lower plate-like member 220B also changes due to the change of the clearance. The pressing force, which has changed, is elastically received by the lower plate-like member 220B arranged along the bottom flat face of the electrochemical element stack S and the flat face of the lower plate 230B in a state of being substantially uniformly scattered on the substantially entire bottom flat face of the electrochemical element stack S and the substantially entire flat face of the lower plate 230B.

Accordingly, even when the clearance between the electrochemical element stack S and the container 200 changes due to expansion of the electrochemical element stack S and the like, appropriate clamping pressure in the stacking direction can be substantially uniformly applied along the flat faces of the electrochemical element stack S due to the lower plate-like member 220B.

Employing the simple configuration as described above in which the lower plate-like member 220B is arranged along the flat faces of the electrochemical element stack S and the lower plate 230B in a location between the bottom flat face of the electrochemical element stack S and the flat face of the plate 230 and these members are housed in the container 200 makes it possible to form the electrochemical module M in which expansion of the electrochemical element stack S and the like is taken into consideration.

It should be noted that, in the case where the lower plate-like member 220B is a member having a small thermal expansion rate, it is preferable to apply larger clamping pressure when the lower plate-like member 220B, the electrochemical element stack S, and the like are housed in the container 200 and assembled together, compared with the case where the lower plate-like member 220B is a member having a large thermal expansion rate. In this case, during assembly, large repulsive force is generated in the lower plate-like member 220B due to large clamping pressure. Accordingly, even when the clearance between the electrochemical element stack S and the container 200 increases in size due to expansion of the electrochemical element stack S and the like, and thus the clamping pressure decreases to a certain degree, appropriate clamping pressure can be applied to the electrochemical element stack S.

(b) In the description above, the lower plate-like member 220B is formed in a wavelike shape, but there is no limitation to this shape, and other configurations can also be employed in which the lower plate-like member 220B is in contact with the electrochemical element stack S, the plates 230, and the like at a plurality of positions that are scattered. For example, the lower plate-like member 220B may also be formed in a leaf-spring shape having a protrusion, a shape obtained by stacking the above-mentioned leaf-springs, or a metal honeycomb shape.

The lower plate-like member 220B may also be in contact with either the bottom flat face of the electrochemical element stack S or the flat face of the lower plate 230B at a plurality of positions that are scattered.

For example, it is also possible that the lower plate-like member 220B is in contact with the bottom flat face of the electrochemical element stack S at a plurality of positions that are scattered, and is in surface contact with the flat face of the lower plate 230B. In this case, a force applied due to expansion of the electrochemical element stack S and the like is scattered and received by the portions of the lower plate-like member 220B that are in contact with the electrochemical element stack S.

Moreover, for example, it is also possible that the lower plate-like member 220B is in surface contact with the bottom flat face of the electrochemical element stack S, and is in contact with the flat face of the lower plate 230B at a plurality of positions.

In this case, a force applied due to expansion of the electrochemical element stack S and the like is scattered and received by the portions of the lower plate-like member 220B that are in contact with the flat face of the lower plate 230B.

(c) In the description above, the lower plate-like member 220B has a thermal expansion rate larger than the thermal expansion rates of the members included in the container 200. However, there is no limitation to such a relationship between the thermal expansion rates as long as a clearance between the electrochemical element stack S and the container 200 formed due to thermal expansion can be compensated with expansion of the lower plate-like member 220B.

For example, the lower plate-like member 220B may have a thermal expansion rate similar to, or smaller than, the thermal expansion rates of the members included in the container 200.

(d) In the description above, the lower plate-like member 220B is used to adjust a change of the clearance between the electrochemical element stack S and the container 200 due to expansion. However, the lower plate-like member 220B can also be employed to adjust a change of the clearance between the electrochemical element stack S and the container 200 due to contraction.

(e) The above-mentioned lower plate-like member 220B can receive expansion and contraction of the electrochemical element stack S, the container 200, and the like caused by a change of the temperature due to power generation as well as changes of, for example, vibration, external pressure, humidity, and outside air temperature that act on the electrochemical module M.

(f) In the description above, the electrochemical module M is provided with functional layers such as the insulators 210 having insulating properties. The electrochemical module M may also be provided with separate functional layers in addition to, or instead of, the above-mentioned functional layers.

(g) In the description above, the lower cover 203 and the upper cover 201 are linked to each other through welding. However, the technique for linking the lower cover 203 and the upper cover 201 to each other is not limited to welding, and the lower cover 203 and the upper cover 201 may be linked to each other using, for example, bolts or the like.

(6) Other Aspects of Electrochemical Module M

Hereinafter, aspects of the electrochemical module M that are different from the electrochemical module M of the above-mentioned embodiment will be described using another aspect 1 and another aspect 2 as examples.

(6-1) Another Aspect 1

An electrochemical module M1 according to another aspect 1 will be described with reference to FIG. 5. The electrochemical module M1 according to the other aspect 1 is different from the electrochemical module M shown in FIG. 1 in that a lower plate-like member 320B is provided in addition to the lower plate-like member 220B. That is, the electrochemical module M1 according to the other aspect 1 is provided with two types of lower plate-like members 220B and 320B.

As shown in FIG. 5, the electrochemical module M1 includes, on the upside of the electrochemical element stack S, the upper insulator 210T and the upper plate 230T, which are arranged in the stated order from the electrochemical element stack S side toward the outside. Similarly, the electrochemical module M1 includes, on the underside of the electrochemical element stack S, the lower insulator 210B, a lower plate-like member 320B, the lower plate-like member 220B, and the lower plate 230B, which are arranged in the stated order from the electrochemical element stack S side toward the outside.

In FIG. 5, the lower plate-like member 320B is a plate-like member having, for example, a metal honeycomb shape. On the other hand, the lower plate-like member 220B is a plate-like member having, for example, a wavelike shape. The functions and effects of the electrochemical module M1 provided with the lower plate-like member 320B and the lower plate-like member 220B are the same as those of the electrochemical module M shown in FIG. 1. The other configurations of the electrochemical module M1 are the same as those of the electrochemical module M shown in FIG. 1, and the descriptions thereof are omitted.

It should be noted that the electrochemical module M1 shown in FIG. 5 may have a configuration in which the lower plate-like member 320B is a plate-like member having a wavelike shape, and the lower plate-like member 220B is a plate-like member having a metal honeycomb shape.

(6-2) Another Aspect 2

An electrochemical module M2 according to another aspect 2 will be described with reference to FIG. 6. The electrochemical module M2 according to the other aspect 2 is mainly different from the electrochemical module M1 shown in FIG. 5 in that the flat face portion 201 a of the upper cover 201 is not provided with the opening 201 d, the first end portion 203 b corresponding to the side face of the lower cover 203 is not provided with an opening 201 e, and the upper plate 230T and the lower plate 230B are omitted.

Furthermore, the electrochemical module M2 is different from the electrochemical module M1 shown in FIG. 5 in that the lower cover 203 and the upper cover 201 are linked to each other using bolts as shown in FIGS. 7 and 8. Specifically, an edge portion 205 of the lower cover 203 and an edge portion 202 of the upper cover 201 are opposed to each other, and a plurality of fastening members 250 are fastened to the edge portions 202 and 205 at a plurality of positions. Each of the fastening members 250 includes a bolt 251 including a head portion and a shaft portion, and a nut 253. The shaft portion of the bolt 251 is inserted through through holes provided in the edge portion 205 of the lower cover 203 and the edge portion 202 of the upper cover 201, and the nut 253 is fastened to the bolt 251. Thus, the edge portion 205 of the lower cover 203 and the edge portion 202 of the upper cover 201 are linked to each other.

However, the lower cover 203 and the upper cover 201 may also be linked to each other through welding in the same manner as shown in FIG. 5.

The following is a further description of FIG. 6. The electrochemical module M2 includes the upper insulator 210T on the upside of the electrochemical element stack S and the outside of the electrochemical element stack S. In this case, the upper insulator 210T is not arranged in a space surrounded by the flat face portion 201 a, the first gas supply portion 61, and the second end portion 201 b, and a space surrounded by the flat face portion 201 a, the first gas discharge portion 62, and the second end portion 201 b.

The electrochemical module M2 also includes, on the underside of the electrochemical element stack S, the lower insulator 210B, the lower plate-like member 320B having, for example, a metal honeycomb shape, and the lower plate-like member 220B having, for example, a wavelike shape, which are arranged in the stated order from the electrochemical element stack S side toward the outside.

The flat face portion 201 a of the upper cover 201 is opposed to the top flat face of the electrochemical element stack S, and the flat face portion 203 a of the lower cover 203 is opposed to the bottom flat face of the electrochemical element stack S. By linking the upper cover 201 and the lower cover 203 to each other, clamping pressure is applied to the electrochemical element stack S substantially uniformly over the flat faces thereof from the flat face portion 201 a and the flat face portion 203 a via the lower plate-like members 220B and 320B.

It should be noted that a configuration may also be employed in which at least either the lower plate-like member 220B or the lower plate-like member 320B is provided. A configuration may also be employed in which the upper insulator 210T is also arranged in a space surrounded by the flat face portion 201 a, the first gas supply portion 61, and the second end portion 201 b, and a space surrounded by the flat face portion 201 a, the first gas discharge portion 62, and the second end portion 201 b.

(7) Specific Configuration of Electrochemical Element Stack S

Next, the specific configuration of the electrochemical element stack S will be described. The electrochemical element stack S is formed by stacking a plurality of electrochemical elements A.

The electrochemical element A will be described with reference to FIGS. 9 to 18.

Electrochemical Element

As shown in FIGS. 9 to 17, the electrochemical element A includes a plate-like support (substrate) 10 provided with the internal passage A1 formed between the faces of the conductive first plate-like body 1 and the conductive second plate-like body 2 that are opposed to each other.

The plate-like support 10 includes the gas-permeable portion 1A through which gas is permeable between the internal passage A1, which is located inside the plate-like support 10, and the outside at one or more portions of the first plate-like body 1 and the second plate-like body 2 included in the plate-like support 10, and the electrochemical reaction portion 3 that entirely or partially covers the gas-permeable portion 1A and includes the film-like electrode layer 31, the film-like electrolyte layer 32 and the film-like counter electrode layer 33 in the stated order (see FIGS. 13 to 17). Moreover, the first penetrated portion 41 forming the supply passage 4 for supplying first gas that is one of reducing component gas such as fuel gas and oxidative component gas such as air from the outside in the surface penetration direction to the internal passage A1 is provided at one end portion of the plate-like support 10, and the second penetrated portion 51 forming the discharge passage 5 for discharging the first gas that has passed through the internal passage A1 to the outside in the surface penetration direction of the plate-like support is provided at the other end portion of the plate-like support 10 (see FIGS. 9, 11, 16, and 17; it is understood that the supply passage 4 and the like and the discharge passage 5 and the like are symmetrical to each other and have a similar structure).

Plate-Like Support

The first plate-like body 1 serves to maintain the strength of the electrochemical element A by supporting the electrochemical reaction portion 3 that includes the electrode layer 31, the electrolyte layer 32, and the counter electrode layer 33. A material that has excellent electron conductivity, thermal resistance, oxidation resistance, and corrosion resistance is used as the material of the first plate-like body 1. Examples thereof include ferrite-based stainless steel, austenite-based stainless steel, and a nickel-based alloy. In particular, an alloy containing chromium is favorably used. In this embodiment, the first plate-like body 1 is made of a Fe—Cr based alloy that contains Cr in an amount of 18 mass % or more and 25 mass % or less, but a Fe—Cr based alloy that contains Mn in an amount of 0.05 mass % or more, a Fe—Cr based alloy that contains Ti in an amount of 0.15 mass % or more and 1.0 mass % or less, a Fe—Cr based alloy that contains Zr in an amount of 0.15 mass % or more and 1.0 mass % or less, a Fe—Cr based alloy that contains Ti and Zr, a total content of Ti and Zr being 0.15 mass % or more and 1.0 mass % or less, and a Fe—Cr based alloy that contains Cu in an amount of 0.10 mass % or more and 1.0 mass % or less are particularly favorable.

The plate-like support 10 is formed by welding and integrating peripheral portions 1 a of the second plate-like body 2 and the first plate-like body 1 in a state in which the second plate-like body 2 and the first plate-like body 1 are stacked (see FIGS. 10 to 17). The second plate-like body 2 may be divided into a plurality of portions with respect to the first plate-like body 1. On the contrary, the first plate-like body 1 may be divided into a plurality of portions with respect to the second plate-like body 2. Another means such as bonding or fitting can be employed as the integrating means instead of welding. Portions other than the peripheral portions 1 a may be integrated as long as the internal passage can be formed separate from the outside.

The first plate-like body 1 includes the gas-permeable portion 1A obtained by forming a large number of through holes 11 that penetrate the surface on the front side and the surface on the back side (see FIGS. 13 to 17). It should be noted that the through holes 11 can be formed in the first plate-like body 1 by, for example, laser processing or the like. The through holes 11 have a function of transmitting gas from the surface on the back side of the first plate-like body 1 to the surface on the front side thereof. It is preferable that the gas-permeable portion 1A is provided in a region of the first plate-like body 1 that is smaller than the region in which the electrode layer 31 is provided.

A metal oxide layer 12 (which will be described later: see FIG. 18) serving as a diffusion suppressing layer is provided on the surface of the first plate-like body 1. That is, the diffusion suppressing layer is formed between the first plate-like body 1 and the electrode layer 31, which will be described later. The metal oxide layer 12 is provided not only on the surface of the first plate-like body 1 exposed to the outside but also the surface (interface) that is in contact with the electrode layer 31. The metal oxide layer 12 can also be provided on the inner faces of the through holes 11. Element interdiffusion that occurs between the first plate-like body 1 and the electrode layer 31 can be suppressed due to this metal oxide layer 12. For example, when ferrite-based stainless steel containing chromium is used in the first plate-like body 1, the metal oxide layer 12 is mainly made of a chromium oxide. The metal oxide layer 12 containing the chromium oxide as the main component suppresses diffusion of chromium atoms and the like of the first plate-like body 1 to the electrode layer 31 and the electrolyte layer 32. The metal oxide layer 12 need only have such a thickness that allows both high diffusion preventing performance and low electric resistance to be achieved.

The metal oxide layer 12 can be formed using various techniques, but it is favorable to use a technique of oxidizing the surface of the first plate-like body 1 to obtain a metal oxide. Also, the metal oxide layer 12 may be formed on the surface of the first plate-like body 1 by using a spray coating technique (a technique such as thermal spraying technique, an aerosol deposition technique, an aerosol gas deposition technique, a powder jet deposition technique, a particle jet deposition technique, or a cold spraying technique), a PVD technique such as a sputtering technique or PLD technique, or a CVD technique, or may be formed by plating and oxidation treatment. Furthermore, the metal oxide layer 12 may also contain a spinel phase that has high electrical conductivity, or the like.

When a ferrite-based stainless steel material is used to form the first plate-like body 1, its thermal expansion coefficient is close to that of YSZ (yttria-stabilized zirconia), GDC (gadolinium-doped ceria; also called CGO), or the like, which is used as the material of the electrode layer 31 and the electrolyte layer 32. Accordingly, even if low and high temperature cycling is repeated, the electrochemical element A is not likely to be damaged. Therefore, this is preferable due to being able to realize an electrochemical element A that has excellent long-term durability. It should be noted that the first plate-like body 1 is provided with a plurality of through holes 11 that penetrate the surface on the front side and the surface on the back side. It should be noted that the through holes 11 can be provided in the first plate-like body 1 through, for example, mechanical, chemical, or optical piercing processing. The through holes 11 have a function of transmitting gas from the surface on the back side of the first plate-like body 1 to the surface on the front side thereof. Porous metal can also be used to impart gas permeability to the first plate-like body 1. For example, a metal sintered body, a metal foam, or the like can also be used as the first plate-like body 1.

The second plate-like body 2 is formed in a wavelike shape such that the internal passage A1 that includes a plurality of auxiliary passages A11 leading from one end side to the other end side is formed in the region opposed to the gas-permeable portion 1A of the first plate-like body 1 (see FIGS. 9 and 13). Both faces on the front side and the back side of the second plate-like body 2 are formed in a wavelike shape. A face on a side opposite to the face that delimits and forms the internal passage A1 is electrically connected to the electrochemical reaction portion 3 of the adjacent electrochemical element A, and passages formed near the portions of the wavelike second plate-like body 2 that are in contact with the first plate-like body 1 function as the flowing portion A2. The plurality of auxiliary passages A11 are provided in parallel along the long side of the rectangular plate-like support 10, and form the internal passage A1 extending from the supply passage 4 provided at one end portion to the discharge passage 5 provided at the other end portion. A connection portion where the first penetrated portion 41 and the internal passage A1 are connected to each other is provided with the distribution portion A12 that is formed by bulging the second plate-like body 2 downward from the portion thereof in contact with the first plate-like body 1 and distributes first gas supplied from the first penetrated portion 41 to the auxiliary passages A11 (see FIG. 9), and a connection portion where the second penetrated portion 51 and the internal passage A1 are connected to each other is provided with the confluence portion A13 that is formed by bulging the second plate-like body 2 downward from the portion thereof in contact with the first plate-like body 1, and collects the first gas that has passed through the auxiliary passages A11 and introduces it into the second penetrated portion 51 (see FIGS. 9, 11, 12, and 14 to 17; it is understood that the supply passage 4 and the like and the discharge passage 5 and the like are symmetrical to each other and have a similar structure). The material of the second plate-like body 2 is preferably a heat resistant metal, and more preferably the same material as that of the first plate-like body 1 from the viewpoint of reducing a difference in thermal expansion between the second plate-like body 2 and the first plate-like body 1 and ensuring the reliability of the joining state due to welding or the like.

The electrode layer 31, the electrolyte layer 32, the counter electrode layer 33, and the like are formed on the top face of the plate-like support 10 constituted by the first plate-like body 1 and the second plate-like body 2 described above. That is, the electrode layer 31, the electrolyte layer 32, the counter electrode layer 33, and the like are supported by the plate-like support 10, and it is possible to realize an electrochemical element A that has high strength and excellent reliability and durability. A plate-like support 10 that is made of a metal has excellent processability, and is thus preferable. Furthermore, even if an inexpensive metal is used for the plate-like support 10, the obtained plate-like support 10 has high strength, and accordingly, the thicknesses of the electrode layer 31, the electrolyte layer 32, and the like, which are expensive, can be reduced, and a low-cost electrochemical element A can be realized with a reduced material cost and a reduced processing cost, which is preferable.

Electrochemical Reaction Portion

Electrode Layer

As shown in FIGS. 13 to 18, the electrode layer 31 can be provided as a thin layer in a region that is larger than the region provided with the through holes 11, on the front face of the first plate-like body 1. When it is formed as a thin layer, the thickness can be set to, for example, approximately 1 μm to 100 μm, and preferably 5 μm to 50 μm. This thickness makes it possible to ensure sufficient electrode performance while also achieving cost reduction by reducing the used amount of expensive electrode layer material. The region provided with the through holes 11 is entirely covered by the electrode layer 31. That is, the through holes 11 are formed inside the region of the first plate-like body 1 in which the electrode layer 31 is formed. In other words, all the through holes 11 are provided facing the electrode layer 31.

The inside and the surface of the electrode layer 31 are provided with a plurality of pores in order to impart gas permeability to the electrode layer 31.

That is, the electrode layer 31 is formed as a porous layer. The electrode layer 31 is formed, for example, to have a denseness of 30% or more and less than 80%. Regarding the size of the pores, a size suitable for smooth progress of an electrochemical reaction can be selected as appropriate. It should be noted that the “denseness” is a ratio of the material of the layer to the space and can be represented by a formula “1—porosity”, and is equivalent to relative density.

For example, a composite material such as NiO-GDC, Ni-GDC, NiO—YSZ, Ni—YSZ, CuO—CeO₂, or Cu—CeO₂ can be used as the material of the electrode layer 31. In these examples, GDC, YSZ, and CeO₂ can be called the aggregate of the composite material. It should be noted that it is preferable to form the electrode layer 31 using low-temperature calcining (not performing calcining treatment in a high temperature range of higher than 1100° C., but rather performing a wet process using calcining treatment in a low temperature range, for example), a spray coating technique (a technique such as a thermal spraying technique, an aerosol deposition technique, an aerosol gas deposition technique, a powder jet deposition technique, a particle jet deposition technique, or a cold spraying technique), a PVD technique (e.g., a sputtering technique or a pulse laser deposition technique), a CVD technique, or the like. Due to these processes that can be used in a low temperature range, a favorable electrode layer 31 is obtained, for example, without using calcining in a high temperature range of higher than 1100° C. Therefore, this is preferable due to being able to prevent damage to the first plate-like body 1, suppress element interdiffusion between the first plate-like body 1 and the electrode layer 31, and realize an electrochemical element A that has excellent durability. Furthermore, using low-temperature calcining makes it possible to facilitate handling of raw materials and is thus more preferable.

Intermediate Layer

An intermediate layer 34 can be formed as a thin layer on the electrode layer 31 so as to cover the electrode layer 31. When it is formed as a thin layer, the thickness can be set to, for example, approximately 1 μm to 100 μm, preferably approximately 2 μm to 50 μm, and more preferably approximately 4 μm to 25 μm.

This thickness makes it possible to ensure sufficient performance while also achieving cost reduction by reducing the used amount of expensive material of the intermediate layer 34. YSZ (yttria-stabilized zirconia), SSZ (scandia-stabilized zirconia), GDC (gadolinium-doped ceria), YDC (yttrium-doped ceria), SDC (samarium-doped ceria), or the like can be used as the material of the intermediate layer 34. In particular, ceria-based ceramics are favorably used.

It is preferable to form the intermediate layer 34 using low-temperature calcining (not performing calcining treatment in a high temperature range of higher than 1100° C., but rather performing a wet process using calcining treatment in a low temperature range, for example), a spray coating technique (a technique such as a thermal spraying technique, an aerosol deposition technique, an aerosol gas deposition technique, a powder jet deposition technique, a particle jet deposition technique, or a cold spraying technique), a PVD technique (e.g., a sputtering technique or a pulse laser deposition technique), a CVD technique, or the like. Due to these film formation processes that can be used in a low temperature range, an intermediate layer 34 is obtained, for example, without using calcining in a high temperature range of higher than 1100° C. Therefore, this is preferable due to being able to prevent damage to the first plate-like body 1, suppress element interdiffusion between the first plate-like body 1 and the electrode layer 31, and realize an electrochemical element A that has excellent durability. Furthermore, using low-temperature calcining makes it possible to facilitate handling of raw materials and is thus more preferable.

It is preferable that the intermediate layer 34 has oxygen ion (oxide ion) conductivity. It is more preferable that the intermediate layer 34 has both oxygen ion (oxide ion) conductivity and electron conductivity, namely mixed conductivity. The intermediate layer 34 that has these properties is suitable for application to the electrochemical element A.

Electrolyte Layer

As shown in FIGS. 13 to 18, the electrolyte layer 32 is formed as a thin layer on the intermediate layer 34 so as to cover the electrode layer 31 and the intermediate layer 34. The electrolyte layer 32 can also be formed as a thin film having a thickness of 10 μm or less. Specifically, the electrolyte layer 32 is provided on both the intermediate layer 34 and the first plate-like body 1 (spanning the intermediate layer 34 and the first plate-like body 1). Configuring the electrolyte layer 32 in this manner and joining the electrolyte layer 32 to the first plate-like body 1 make it possible to allow the electrochemical element to have excellent toughness as a whole.

Also, as shown in FIG. 13, the electrolyte layer 32 is provided in a region that is larger than the region provided with the through holes 11, on the front face of the first plate-like body 1. That is, the through holes 11 are formed inside the region of the first plate-like body 1 in which the electrolyte layer 32 is formed.

The leakage of gas from the electrode layer 31 and the above-mentioned intermediate layer (not shown) can be suppressed in the vicinity of the electrolyte layer 32. A description of this will be given. When the electrochemical element A is used as a constituent element of a SOFC, gas is supplied from the back side of the first plate-like body 1 through the through holes 11 to the electrode layer 31 during the operation of the SOFC. In a region where the electrolyte layer 32 is in contact with the first plate-like body 1, leakage of gas can be suppressed without providing another member such as a gasket. It should be noted that although the entire vicinity of the electrode layer 31 is covered by the electrolyte layer 32 in this embodiment, a configuration in which the electrolyte layer 32 is provided on the electrode layer 31 and the above-mentioned intermediate layer 34 and a gasket or the like is provided in its vicinity may also be adopted.

Electrolyte materials having oxygen ion conductivity such as YSZ (yttria-stabilized zirconia), SSZ (scandia-stabilized zirconia), GDC (gadolinium-doped ceria), YDC (yttrium-doped ceria), SDC (samarium-doped ceria), LSGM (strontium- and magnesium-doped lanthanum gallate), and the like, and electrolyte materials having hydrogen ion conductivity such as perovskite oxides can be used as the material of the electrolyte layer 32. In particular, zirconia-based ceramics are favorably used. Using zirconia-based ceramics for the electrolyte layer 32 makes it possible to increase the operation temperature of the SOFC in which the electrochemical element A is used compared with the case where ceria-based ceramics and various materials having hydrogen ion conductivity are used. For example, when the electrochemical element A is used in the SOFC, by adopting a system configuration in which a material such as YSZ that can exhibit high electrolyte performance even in a high temperature range of approximately 650° C. or higher is used as the material of the electrolyte layer 32, a hydrocarbon-based raw fuel material such as city gas or LPG is used as the raw fuel for the system, and the raw fuel material is reformed into anode gas of the SOFC through steam reforming or the like, it is thus possible to construct a high-efficiency SOFC system in which heat generated in a cell stack of the SOFC is used to reform raw fuel gas.

It is preferable to form the electrolyte layer 32 using low-temperature calcining (not performing calcining treatment in a high temperature range of higher than 1100° C., but rather performing a wet process using calcining treatment in a low temperature range, for example), a spray coating technique (a technique such as a thermal spraying technique, an aerosol deposition technique, an aerosol gas deposition technique, a powder jet deposition technique, a particle jet deposition technique, or a cold spraying technique), a PVD technique (e.g., a sputtering technique or a pulse laser deposition technique), a CVD (chemical vapor deposition) technique, or the like. Due to these film formation processes that can be used in a low temperature range, an electrolyte layer 32 that is dense and has high gas-tightness and gas barrier properties is obtained, for example, without using calcining in a high temperature range of higher than 1100° C. Therefore, it is possible to prevent damage to the first plate-like body 1, suppress element interdiffusion between the first plate-like body 1 and the electrode layer 31, and realize an electrochemical element A that has excellent performance and durability. In particular, using low-temperature calcining, a spray coating technique, or the like makes it possible to realize a low-cost element and is thus preferable. Furthermore, using a spray coating technique makes it easy to obtain, in a low temperature range, an electrolyte layer that is dense and has high gas-tightness and gas barrier properties, and is thus more preferable.

The electrolyte layer 32 is given a dense configuration in order to block gas leakage of anode gas and cathode gas and exhibit high ion conductivity. The electrolyte layer 32 preferably has a denseness of 90% or more, more preferably 95% or more, and even more preferably 98% or more. When the electrolyte layer 32 is formed as a uniform layer, the denseness is preferably 95% or more, and more preferably 98% or more. When the electrolyte layer 32 has a multilayer configuration, at least a portion thereof preferably includes a layer (dense electrolyte layer) having a denseness of 98% or more, and more preferably a layer (dense electrolyte layer) having a denseness of 99% or more. The reason for this is that an electrolyte layer that is dense and has high gas-tightness and gas barrier properties can be easily formed due to such a dense electrolyte layer being included as a portion of the electrolyte layer even when the electrolyte layer has a multilayer configuration.

Reaction Preventing Layer

A reaction preventing layer 35 can be formed as a thin layer on the electrolyte layer 32. When it is formed as a thin layer, the thickness can be set to, for example, approximately 1 μm to 100 μm, preferably approximately 2 μm to 50 μm, and more preferably approximately 3 μm to 15 μm. This thickness makes it possible to ensure sufficient performance while also achieving cost reduction by reducing the used amount of expensive reaction preventing layer material. The material of the reaction preventing layer need only be capable of preventing reactions between the component of the electrolyte layer 32 and the component of the counter electrode layer 33. For example, a ceria-based material or the like is used. Materials that contain at least one element selected from the group consisting of Sm, Gd, and Y are favorably used as the material of the reaction preventing layer 35. It is preferable that at least one element selected from the group consisting of Sm, Gd, and Y is contained, and the total content of these elements is 1.0 mass % or more and 10 mass % or less. Introducing the reaction preventing layer 35 between the electrolyte layer 32 and the counter electrode layer 33 effectively suppresses reactions between the material constituting the counter electrode layer 33 and the material constituting the electrolyte layer 32 and makes it possible to improve long-term stability in the performance of the electrochemical element A. Forming the reaction preventing layer 35 using, as appropriate, a method through which the reaction preventing layer 35 can be formed at a treatment temperature of 1100° C. or lower makes it possible to suppress damage to the first plate-like body 1, suppress element interdiffusion between the first plate-like body 1 and the electrode layer 31, and realize an electrochemical element A that has excellent performance and durability, and is thus preferable. For example, the reaction preventing layer 35 can be formed using, as appropriate, low-temperature calcining (not performing calcining treatment in a high temperature range of higher than 1100° C., but rather performing a wet process using calcining treatment in a low temperature range, for example), a spray coating technique (a technique such as a thermal spraying technique, an aerosol deposition technique, an aerosol gas deposition technique, a powder jet deposition technique, a particle jet deposition technique, or a cold spraying technique), a PVD technique (e.g., a sputtering technique or a pulse laser deposition technique), a CVD technique, or the like. In particular, using low-temperature calcining, a spray coating technique, or the like makes it possible to realize a low-cost element and is thus preferable. Furthermore, using low-temperature calcining makes it possible to facilitate handling of raw materials and is thus more preferable.

Counter Electrode Layer

As shown in FIGS. 13 to 18, the counter electrode layer 33 can be formed as a thin layer on the electrolyte layer 32 or the reaction preventing layer 35. When it is formed as a thin layer, the thickness can be set to, for example, approximately 1 μm to 100 μm, and preferably 5 μm to 50 μm. This thickness makes it possible to ensure sufficient electrode performance while also achieving cost reduction by reducing the used amount of expensive counter electrode layer material. For example, a complex oxide such as LSCF or LSM, or a ceria-based oxide, or a mixture thereof can be used as the material of the counter electrode layer 33, for example. In particular, it is preferable that the counter electrode layer 33 includes a perovskite oxide containing two or more elements selected from the group consisting of La, Sr, Sm, Mn, Co, and Fe. The counter electrode layer 33 constituted by the above-mentioned material functions as a cathode.

It should be noted that forming the counter electrode layer 33 using, as appropriate, a method through which the counter electrode layer 33 can be formed at a treatment temperature of 1100° C. or lower makes it possible to suppress damage to the first plate-like body 1, suppress element interdiffusion between the first plate-like body 1 and the electrode layer 31, and realize an electrochemical element A that has excellent performance and durability, and is thus preferable. For example, the counter electrode layer 33 can be formed using, as appropriate, low-temperature calcining (not performing calcining treatment in a high temperature range of higher than 1100° C., but rather performing a wet process using calcining treatment in a low temperature range, for example), a spray coating technique (a technique such as a thermal spraying technique, an aerosol deposition technique, an aerosol gas deposition technique, a powder jet deposition technique, a particle jet deposition technique, or a cold spraying technique), a PVD technique (e.g., a sputtering technique or a pulse laser deposition technique), a CVD technique, or the like. In particular, using low-temperature calcining, a spray coating technique, or the like makes it possible to realize a low-cost element and is thus preferable. Furthermore, using low-temperature calcining makes it possible to facilitate handling of raw materials and is thus more preferable.

By configuring the electrochemical reaction portion 3 as described above, the electrochemical element A can be used as a power generating cell for a solid oxide fuel cell when the electrochemical reaction portion 3 is allowed to function as a fuel cell (electrochemical power generating cell). For example, fuel gas containing hydrogen serving as first gas is supplied from the back face of the first plate-like body 1 through the through holes 11 to the electrode layer 31, air serving as second gas is supplied to the counter electrode layer 33 serving as a counter electrode of the electrode layer 31, and the temperature is maintained at the operation temperature of, for example, approximately 700° C. Accordingly, the oxygen O₂ included in air reacts with electrons e⁻ in the counter electrode layer 33, thus producing oxygen ions O²⁻. The oxygen ions O²⁻ move to the electrode layer 31 through the electrolyte layer 32. In the electrode layer 31, the hydrogen 112 included in the supplied fuel gas reacts with the oxygen ions O²⁻, thus producing water H₂O and electrons e⁻.

When the electrolyte layer 32 is made of an electrolyte material having hydrogen ion conductivity, hydrogen 112 included in the fuel gas flowing in the electrode layer 31 releases electrons e⁻, thus producing hydrogen ions H⁺. The hydrogen ions H⁺ move to the counter electrode layer 33 through the electrolyte layer 32. In the counter electrode layer 33, oxygen O₂ included in air, hydrogen ions H⁺, and electrons e⁻ react with each other to produce water H₂O.

With these reactions, an electromotive force as electrochemical output is generated between the electrode layer 31 and the counter electrode layer 33. In this case, the electrode layer 31 functions as a fuel electrode (anode) of the fuel cell, and the counter electrode layer 33 functions as an air electrode (cathode).

Although omitted in FIGS. 13 to 17, the intermediate layer 34 is provided between the electrode layer 31 and the electrolyte layer 32 of the electrochemical reaction portion 3 of this embodiment as shown in FIG. 18. Furthermore, the reaction preventing layer 35 is provided between the electrolyte layer 32 and the counter electrode layer 33.

Method for Manufacturing Electrochemical Reaction Portion

Next, a method for manufacturing the electrochemical reaction portion 3 will be described. It should be noted that the description will be given mainly with reference to FIG. 18 since the intermediate layer 34 and the reaction preventing layer 35 are omitted in FIGS. 13 to 17.

Electrode Layer Forming Step

In an electrode layer forming step, the electrode layer 31 is formed as a thin film in a region that is broader than the region provided with the through holes 11, on the front face of the first plate-like body 1. The through holes 11 of the first plate-like body 1 can be provided through laser processing or the like. As described above, the electrode layer 31 can be formed using low-temperature calcining (a wet process using calcining treatment in a low temperature range of 1100° C. or lower), a spray coating technique (a technique such as a thermal spraying technique, an aerosol deposition technique, an aerosol gas deposition technique, a powder jet deposition technique, a particle jet deposition technique, or a cold spraying technique), a PVD technique (e.g., a sputtering technique or a pulse laser deposition technique), a CVD technique, or the like. Regardless of which technique is used, it is desirable to perform the technique at a temperature of 1100° C. or lower in order to suppress deterioration of the first plate-like body 1.

The following is a specific example of the case where low-temperature calcining is performed as the electrode layer forming step. First, a material paste is produced by mixing powder of the material of the electrode layer 31 and a solvent (dispersion medium), and is applied to the front face of the first plate-like body 1. Then, calcining is performed at a temperature of 800° C. to 1100° C.

Diffusion Suppressing Layer Forming Step

The metal oxide layer 12 (diffusion suppressing layer) is formed on the surface of the first plate-like body 1 during the calcining step in the above-described electrode layer forming step. It should be noted that it is preferable that the above-mentioned calcining step includes a calcining step in which the calcining atmosphere satisfies the atmospheric condition that the oxygen partial pressure is low because a high-quality metal oxide layer 12 (diffusion suppressing layer) that has a high element interdiffusion suppressing effect and has a low resistance value is formed. In a case where a coating method that does not include calcining is performed as the electrode layer forming step, for example, a separate diffusion suppressing layer forming step may also be included. In any case, it is desirable to perform these steps at a temperature of 1100° C. or lower such that damage to the first plate-like body 1 can be suppressed.

Intermediate Layer Forming Step

In an intermediate layer forming step, the intermediate layer 34 is formed as a thin layer on the electrode layer 31 so as to cover the electrode layer 31. As described above, the intermediate layer 34 can be formed using low-temperature calcining (a wet process using calcining treatment in a low temperature range of 1100° C. or lower), a spray coating technique (a technique such as a thermal spraying technique, an aerosol deposition technique, an aerosol gas deposition technique, a powder jet deposition technique, a particle jet deposition technique, or a cold spraying technique), a PVD technique (e.g., a sputtering technique or a pulse laser deposition technique), a CVD technique, or the like. Regardless of which technique is used, it is desirable to perform the technique at a temperature of 1100° C. or lower in order to suppress deterioration of the first plate-like body 1.

The following is a specific example of the case where low-temperature calcining is performed as the intermediate layer forming step.

First, a material paste is produced by mixing powder of the material of the intermediate layer 34 and a solvent (dispersion medium), and is applied to the front face of the first plate-like body 1. Then, the intermediate layer 34 is obtained through compression molding (intermediate layer smoothing step) and calcining at a temperature of 1100° C. or lower (intermediate layer calcining step). Examples of rolling of the intermediate layer 34 include CIP (Cold Isostatic Pressing) molding, roll pressing molding, and RIP (Rubber Isostatic Pressing) molding. It is favorable to perform calcining of the intermediate layer 34 at a temperature of 800° C. or higher and 1100° C. or lower. The reason for this is that this temperature makes it possible to form an intermediate layer 34 that has high strength while suppressing damage to and deterioration of the first plate-like body 1. It is more preferable to perform calcining of the intermediate layer 34 at a temperature of 1050° C. or lower, and more preferably 1000° C. or lower. The reason for this is that the lower the calcining temperature of the intermediate layer 34 is, the more likely it is to further suppress damage to and deterioration of the first plate-like body 1 when forming the electrochemical element A. The order in which the intermediate layer smoothing step and the intermediate layer calcining step are performed can be changed.

It should be noted that lapping molding, leveling treatment, surface cutting treatment, surface polishing treatment, or the like can also be performed as the intermediate layer smoothing step.

Electrolyte Layer Forming Step

In an electrolyte layer forming step, the electrolyte layer 32 is formed as a thin layer on the intermediate layer 34 so as to cover the electrode layer 31 and the intermediate layer 34. The electrolyte layer 32 may also be formed as a thin film having a thickness of 10 μm or less. As described above, the electrolyte layer 32 can be formed using low-temperature calcining (a wet process using calcining treatment in a low temperature range of 1100° C. or lower), a spray coating technique (a technique such as a thermal spraying technique, an aerosol deposition technique, an aerosol gas deposition technique, a powder jet deposition technique, a particle jet deposition technique, or a cold spraying technique), a PVD technique (e.g., a sputtering technique or a pulse laser deposition technique), a CVD technique, or the like. Regardless of which technique is used, it is desirable to perform the technique at a temperature of 1100° C. or lower in order to suppress deterioration of the first plate-like body 1.

It is desirable to perform a spray coating technique as the electrolyte layer forming step in order to form a high-quality electrolyte layer 32 that is dense and has high gas-tightness and gas barrier properties in a temperature range of 1100° C. or lower. In this case, the material of the electrolyte layer 32 is sprayed onto the intermediate layer 34 on the first plate-like body 1, and the electrolyte layer 32 is thus formed.

Reaction Preventing Layer Forming Step

In a reaction preventing layer forming step, the reaction preventing layer 35 is formed as a thin layer on the electrolyte layer 32. As described above, the reaction preventing layer 35 can be formed using low-temperature calcining (a wet process using calcining treatment in a low temperature range of 1100° C. or lower), a spray coating technique (a technique such as a thermal spraying technique, an aerosol deposition technique, an aerosol gas deposition technique, a powder jet deposition technique, a particle jet deposition technique, or a cold spraying technique), a PVD technique (e.g., a sputtering technique or a pulse laser deposition technique), a CVD technique, or the like. Regardless of which technique is used, it is desirable to perform the technique at a temperature of 1100° C. or lower in order to suppress deterioration of the first plate-like body 1. It should be noted that, for example, leveling treatment, surface cutting treatment, or surface polishing treatment may be performed after the formation of the reaction preventing layer 35, or pressing processing may be performed after wet formation and before calcining, in order to flatten the top face of the reaction preventing layer 35.

Counter Electrode Layer Forming Step

In a counter electrode layer forming step, the counter electrode layer 33 is formed as a thin layer on the reaction preventing layer 35. As described above, the counter electrode layer 33 can be formed using low-temperature calcining (a wet process using calcining treatment in a low temperature range of 1100° C. or lower), a spray coating technique (a technique such as a thermal spraying technique, an aerosol deposition technique, an aerosol gas deposition technique, a powder jet deposition technique, a particle jet deposition technique, or a cold spraying technique), a PVD technique (e.g., a sputtering technique or a pulse laser deposition technique), a CVD technique, or the like. Regardless of which technique is used, it is desirable to perform the technique at a temperature of 1100° C. or lower in order to suppress deterioration of the first plate-like body 1.

In this manner, the electrochemical reaction portion 3 can be manufactured.

It should be noted that a configuration in which the electrochemical reaction portion 3 does not include both or either of the intermediate layer 34 and the reaction preventing layer 35 is also possible. That is, a configuration in which the electrode layer 31 and the electrolyte layer 32 are in contact with each other, or a configuration in which the electrolyte layer 32 and the counter electrode layer 33 are in contact with each other is also possible. In this case, in the above-described manufacturing method, the intermediate layer forming step and the reaction preventing layer forming step are omitted. It should be noted that it is also possible to add a step of forming another layer or to form a plurality of layers of the same type one on top of another, but in any case, it is desirable to perform these steps at a temperature of 1100° C. or lower.

Electrochemical Element Stack

As shown in FIG. 4, the electrochemical element stack S is formed by stacking a plurality of electrochemical elements A in a predetermined stacking direction. The electrochemical elements A are arranged such that, regarding the adjacent electrochemical elements A, the plate-like support 10 included in one electrochemical element A (first electrochemical element A) is opposed to the plate-like support 10 included in the other electrochemical element A (second electrochemical element A).

For example, one electrochemical element A (first electrochemical element A) includes the plate-like support 10 that includes the first plate-like body 1 and the second plate-like body 2, on which the first plate-like body 1 the electrochemical reaction portion 3 is arranged. Similarly, the second electrochemical elements A adjacent to the first electrochemical element A on the lower side (first side) and the upper side (second side) thereof each include the plate-like support 10 that includes the first plate-like body 1 and the second plate-like body 2, on which the first plate-like body 1 the electrochemical reaction portion 3 is arranged.

The outer face of the second plate-like body 2 of a first electrochemical element A is electrically connected to the outer face of the first plate-like body 1 of a second electrochemical element A adjacent to the first electrochemical element A on the upper side thereof. The flowing portion A2 through which second gas flows is formed between the outer face of the second plate-like body 2 of a first electrochemical element A and the outer face of the first plate-like body 1 of a second electrochemical element A adjacent to the first electrochemical element A on the upper side thereof, and extends along both of the outer faces.

Moreover, the outer face of the first plate-like body 1 of a first electrochemical element A is electrically connected to the outer face of the second plate-like body 2 of a second electrochemical element A adjacent to the first electrochemical element A on the lower side thereof. As a method for electrically connecting the two outer faces, a method for simply bringing electroconductive surfaces into contact with each other, a method for applying contact pressure to the contact faces, a method for reducing contact resistance by providing a highly electroconductive material therebetween, or the like can be employed. The auxiliary passage A11 (a portion of the internal passage A1) through which first gas flows is formed between the outer face of the first plate-like body 1 of a first electrochemical element A and the outer face of the second plate-like body 2 of a second electrochemical element A adjacent to the first electrochemical element A on the lower side thereof, and extends along both of the outer faces.

A plurality of such electrochemical elements A are arranged in a stacked manner. Specifically, the rectangular electrochemical elements are lined up and stacked in the state in which the first penetrated portions 41 at one end and the second penetrated portions 51 at the other end are respectively aligned and the electrochemical reaction portions of the electrochemical elements face upward. The first annular sealing portions 42 are provided between the first penetrated portions 41, and the second annular sealing portions 52 are provided between the second penetrated portions 51.

In the plate-like support 10, the first penetrated portion 41 forming the supply passage 4 for supplying first gas that is one of reducing component gas and oxidative component gas from the outside in the surface penetration direction to the internal passage A1 is provided at one end in the longitudinal direction of the rectangular plate-like support 10. In the flowing portion A2, the first penetrated portion 41 that is formed on each of the two outer faces of the plate-like member 10 is provided with the first annular sealing portion 42 serving as an annular sealing portion for separating the first penetrated portion 41 from the flowing portion A2. The supply passage 4 for supplying the first gas to the internal passage A1 is formed by the first penetrated portion 41 and the first annular sealing portion 42. It should be noted that the annular bulging portion a is provided around a portion of the first plate-like body 1 with which the first annular sealing portion 42 is in contact, on a face of the first plate-like body 1 on a side opposite to the internal passage A1, thus making it easy to position the first annular sealing portion 42 in the direction along the face of the first plate-like body 1.

Moreover, in the plate-like support 10, the second penetrated portion 51 forming the discharge passage 5 for discharging the first gas that has passed through the internal passage A1 to the outside in the surface penetration direction of the plate-like support 10 is provided at the other end. The second penetrated portion 51 has a configuration in which the first gas flows therein in the state of being separated from the second gas. In the flowing portion A2, the second penetrated portion 51 that is formed on each of the two outer faces of the plate-like support 10 is provided with the second annular sealing portion 52 serving as an annular sealing portion for separating the second penetrated portion 51 from the flowing portion A2. The discharge passage 5 for discharging the first gas that has passed through the internal passage A1 is formed by the second penetrated portion 51 and the second annular sealing portion 52.

The first annular sealing portion 42 and the second annular sealing portion 52 are made of an insulation material such as a ceramics material (e.g., alumina), mica, or a metal covered by the ceramics material or mica, and function as insulating sealing portions that electrically insulate the adjacent electrical elements from each other.

(8) Energy System, Electrochemical Device

Next, an energy system and an electrochemical device will be described with reference to FIG. 19.

An energy system Z includes an electrochemical device 100, and a heat exchanger 190 serving as a waste heat utilization system that reuses heat discharged from the electrochemical device 100.

The electrochemical device 100 includes the electrochemical module M, a fuel supply module, and an inverter (an example of a power converter) 104 serving as the output portion 8 for extracting power from the electrochemical module M. The fuel supply module includes a fuel supply unit 103 that includes a desulfurizer 101, a vaporizer 106, and a reformer 102, and that supplies fuel gas containing a reducing component to the electrochemical module M. It should be noted that the reformer 102 serves as a fuel converter in this case.

Specifically, the electrochemical device 100 includes the desulfurizer 101, a water tank 105, a vaporizer 106, the reformer 102, a blower 107, a combustion unit 108, the inverter 104, a control unit 110, and the electrochemical module M.

The desulfurizer 101 removes sulfur compound components contained in a hydrocarbon-based raw fuel such as city gas (i.e., performs desulfurization). When a sulfur compound is contained in the raw fuel, the inclusion of the desulfurizer 101 makes it possible to suppress an adverse influence that the sulfur compound has on the reformer 102 or the electrochemical elements A. The vaporizer 106 produces water vapor (steam) from water supplied from the water tank 105. The reformer 102 uses the water vapor (steam) produced by the vaporizer 106 to perform steam reforming of the raw fuel desulfurized by the desulfurizer 101, thus producing reformed gas containing hydrogen.

The electrochemical module M generates power by causing an electrochemical reaction to occur with use of the reformed gas supplied from the reformer 102 and air supplied from the blower 107. The combustion unit 108 mixes the reaction exhaust gas discharged from the electrochemical module M with air, and burns combustible components in the reaction exhaust gas.

The inverter 104 adjusts the power output from the electrochemical module M to obtain the same voltage and frequency as power received from a commercial system (not shown). The control unit 110 controls the operation of the electrochemical device 100 and the energy system Z.

The reformer 102 performs reforming process on the raw fuel with use of combustion heat produced by the combustion of reaction exhaust gas in the combustion unit 108.

The raw fuel is supplied to the desulfurizer 101 via a raw fuel supply passage 112, due to operation of a booster pump 111. The water in the water tank 105 is supplied to the vaporizer 106 via a water supply passage 114, due to operation of a water pump 113. The raw fuel supply passage 112 merges with the water supply passage 114 at a location on the downstream side of the desulfurizer 101, and the water and the raw fuel, which have been merged outside of the container 200, are supplied to the vaporizer 106.

The water is vaporized by the vaporizer 106 to produce water vapor. The raw fuel, which contains the water vapor produced by the vaporizer 106, is supplied to the reformer 102 via a water vapor-containing raw fuel supply passage 115. In the reformer 102, the raw fuel is subjected to steam reforming, thus producing reformed gas that contains hydrogen gas as a main component (first gas containing a reducing component). The reformed gas produced in the reformer 102 is supplied to the electrochemical module M via the fuel supply unit 103.

The reaction exhaust gas is burned in the combustion unit 108, and obtained combustion exhaust gas is sent from a combustion exhaust gas discharge passage 116 to the heat exchanger 190. A combustion catalyst unit 117 (e.g., a platinum-based catalyst) is provided in the combustion exhaust gas discharge passage 116, and reducing components such as carbon monoxide and hydrogen contained in the combustion exhaust gas are removed by combustion.

The heat exchanger 190 uses supplied cool water to perform heat exchange on the combustion exhaust gas produced by combustion in the combustion unit 108, thus producing warm water. In other words, the heat exchanger 190 operates as a waste heat utilization system that reuses heat discharged from the electrochemical device 100.

It should be noted that instead of the waste heat utilization system, it is possible to provide a reaction exhaust gas using unit that uses the reaction exhaust gas that is discharged from (not burned in) the electrochemical module M. At least a portion of the reaction exhaust gas flowing from the first gas discharge portion 62 to the outside of the container 200 may be returned to one of the members 100, 101, 103, 106, 112, 113, and 115 shown in FIG. 19 and recycled. The reaction exhaust gas contains remaining hydrogen gas that was not used in the reaction in the electrochemical elements A. In the reaction exhaust gas using unit, the remaining hydrogen gas is used to perform heat utilization through combustion or power generation by a fuel cell and so on, thus achieving effective energy utilization.

OTHER EMBODIMENTS

The configuration disclosed in the embodiment described above (including the other embodiments; the same applies to the following) can be applied in combination with configurations disclosed in the other embodiments as long as no contradiction arises. Also, the embodiments disclosed in this specification are illustrative, embodiments of the present invention are not limited to the disclosed embodiments, and appropriate modifications can be made without departing from the object of the present invention.

(1) In the embodiment above, the electrochemical element stack S is pressed by the pressing mechanisms 400 and the lower plate-like member (first plate-like member) 220B. However, a configuration in which the pressing mechanisms 400 are not provided is also possible. Such a configuration will be described with reference to FIGS. 20 to 23. It should be noted that configurations different from those of the embodiment above will be mainly described, and descriptions of similar configurations will be simplified or omitted.

(1-1) Overall Configuration of Electrochemical Module M

Hereinafter, the overall configuration of the electrochemical module M will be described with reference to FIGS. 20 to 23. As shown in FIG. 20, the electrochemical module M includes an electrochemical element stack (stack) S, and a container (a housing, a first clamping portion, a second clamping portion) 200 that has a substantially rectangular parallelepiped shape and is internally provided with the electrochemical element stack S. Unlike the embodiment above, the pressing mechanisms 400 are not provided.

The electrochemical module M also includes a first gas supply portion (flowing pipe) 61 for supplying first gas to the electrochemical element stack S from the outside of the container 200, and a first gas discharge portion (flowing pipe) 62 for discharging the first gas used in a reaction in the electrochemical element stack S. The container 200 also includes a second gas supply portion 71 for supplying second gas to the electrochemical element stack S from the outside of the container 200, and a second gas discharge portion 72 for discharging the second gas.

The electrochemical module M includes, on the upside of the electrochemical element stack S, an upper insulator 210T and an upper plate (first clamping portion) 230T, which are arranged in the stated order from the electrochemical element stack S side toward the outside. On the other hand, the electrochemical module M includes, on the underside of the electrochemical element stack S, a lower insulator 210B, a lower plate-like member 220B, and a lower plate (second clamping portion) 230B, which are arranged in the stated order from the electrochemical element stack S side toward the outside.

As shown in FIGS. 20 to 22, the container 200 that is internally provided with the electrochemical element stack S has a substantially rectangular parallelepiped shape. The container 200 includes an upper cover 201 having a box shape whose bottom portion is open, and a lower cover 203 whose top portion is open. A coupling portion 202 is provided on the end face of the upper cover 201 that is opposed to the lower cover 203, and a coupling portion 205 is provided on the end face of the lower cover 203 that is opposed to the upper cover 201. The upper cover 201 and the lower cover 203 are coupled to each other by, for example, welding the coupling portion 202 and the coupling portion 205 to each other, and thus a space having a rectangular parallelepiped shape is formed therein.

As shown in FIGS. 20 and 21, the upper cover 201 is provided with an opening 201 c that is slightly smaller in size than the area surrounded by the outer edge of the upper cover 201. In the cross-sectional view shown in FIG. 20, the end portion on the inner side that is adjacent to the opening 201 c and faces the electrochemical element stack S is branched into a first end portion 201 a and a second end portion 201 b. The first end portion 201 a has a predetermined length and extends toward the inside of the container 200 in the plane direction, and the second end portion 201 b has a predetermined length, is branched from the first end portion 201 a, and extends toward the lower side of the container 200. The first end portion 201 a and the second end portion 201 b form an angle of approximately 90° in a cross-sectional view, and form an L-shaped corner portion. This L-shaped corner portion is formed at a position inward of the outer edge of the upper cover 201 shown in FIG. 20 in a top view, and extends along this outer edge. Thus, as shown in FIGS. 20 and 21, the opening 201 c, which is slightly smaller in size than the area surrounded by the outer edge of the upper cover 201, is formed by the end of the first end portion 201 a in the top face of the upper cover 201 as described above.

As in the case of the upper cover 201, the lower cover 203 includes a first end portion 203 a and a second end portion 203 b that form an angle of approximately 90° in the cross-sectional view shown in FIG. 20 and form an L-shaped corner portion. As shown in FIG. 20, an opening 203 c that is slightly smaller in size than the area surrounded by the outer edge of the lower cover 203 is formed by the end of the first end portion 203 a.

As shown in FIG. 20, the upper ends of the two perforated plate members 240, the upper insulator 210T, and the upper plate 230T are fitted onto the L-shaped corner portion formed by the first end portion 201 a and the second end portion 201 b of the upper cover 201.

The lower ends of the two perforated plate members 240, the lower insulator 210B, the lower plate-like member 220B, and the lower plate 230B are fitted onto a pair of L-shaped corner portions that are opposed to each other in the plane direction of the lower cover 203.

The top face of the electrochemical element stack S is supported by the upper cover 201 via the upper plate 230T and the upper insulator 210T. The bottom face of the electrochemical element stack S is supported by the lower cover 203 via the lower plate 230B, the lower plate-like member 220B, and the lower insulator 210B.

As shown in FIG. 23, the through holes of the first penetrated portion 41 and the first annular sealing portions 42 in the electrochemical element stack S are in communication with the first gas supply portion 61 through the opening of the collector 81. Similarly, the through holes of the second penetrated portion 51 and the second annular sealing portions 52 are in communication with the first gas discharge portion 62 through the opening of the collector 81.

The upper cover 201 and the lower cover 203 having these configurations are coupled to each other by, for example, welding the coupling portion 202 and the coupling portion 205 to each other in the state in which the electrochemical element stack S, the upper insulator 210T, the lower insulator 210B, the lower plate-like member 220B, the upper plate 230T, the lower plate 230B, and the like are sandwiched between the upper cover 201 and the lower cover 203 from above and below. During this coupling, the upper cover 201 and the lower cover 203 are coupled to each other while applying predetermined clamping pressure to the electrochemical element stack S and the like.

(1-2) Configurations and Functions of Lower Plate-Like Member and Related Members

The lower plate-like member 220B has a configuration similar to that in the embodiment above.

With the above-mentioned configuration, the electrochemical module M is pressed by the elastic lower plate-like member 220B from the bottom flat face side of the electrochemical element stack S. Thus, the electrochemical element stack S, including the regions on which the first annular sealing portions 42 and the second annular sealing portions 52 are present, is pressed from the bottom flat face side. On the other hand, the first gas supply portion (flowing pipe) 61 and the first gas discharge portion (flowing pipe) 62 are provided on the top flat face side of the electrochemical element stack S.

The plurality of first annular sealing portions 42 and the plurality of second annular sealing portions 52 are pressed upward in the stacking direction from the bottom flat face side of the electrochemical element stack S. Thus, leakage of the first gas through a gap between the first annular sealing portion 42 and another member and a gap between the second annular sealing portion 52 and another member can be suppressed.

Moreover, the electrochemical element stack S is pressed by the lower plate-like member 220B toward the piping including the first gas supply portion 61, the first gas discharge portion 62, and the like to which the first annular sealing portion 42 and the second annular sealing portion 52 are coupled. Accordingly, the connection positions where the first annular sealing portion 42 and the second annular sealing portion 52 are connected to the piping can be substantially fixed. Therefore, the first annular sealing portion 42 and the second annular sealing portion 52 can be fixed to the piping through welding or the like. Accordingly, there is no need to use flexible piping in consideration of a shift of the connection positions where the first annular sealing portion 42 and the second annular sealing portion 52 are connected to the piping, and thus a durable stainless steel pipe or the like can be used for the piping.

It should be noted that, as in the case of FIG. 24 in (2) below, an upper plate-like member (second plate-like member) 220T may also be provided in addition to the lower plate-like member (first plate-like member) 220B in the configuration shown in FIGS. 20 to 23. In this case, the elastic force of the lower plate-like member 220B is larger than the elastic force of the upper plate-like member 220T (the elastic force of the lower plate-like member 220B>the elastic force of the upper plate-like member 220T). This relationship can be achieved by setting the thermal expansion rate of the lower plate-like member 220B to be larger than the thermal expansion rate of the upper plate-like member 220T.

(2) In the embodiment above, only the lower plate-like member (first plate-like member) 220B located on a side of the electrochemical element stack S that is opposite to the pressing mechanisms 400 is provided as a plate-like member. However, as shown in FIG. 24, an upper plate-like member (second plate-like member) 220T may also be provided on the same side as the side on which the pressing mechanisms 400 are provided.

Configurations different from those of the embodiment above will be mainly described below, and descriptions of similar configurations will be simplified or omitted.

(2-1) Overall Configuration of Electrochemical Module M

As shown in FIG. 24, the electrochemical module M includes, on the upside of the electrochemical element stack S, the upper insulator 210T, the upper plate-like member 220T, and the upper plate 230T, which are arranged in the stated order from the electrochemical element stack S side toward the outside. Similarly, the electrochemical module M includes, on the underside of the electrochemical element stack S, the lower insulator 210B, the lower plate-like member 220B, and the lower plate 230B, which are arranged in the stated order from the electrochemical element stack S side toward the outside.

The upper plate-like member 220T is arranged on the top of the upper insulator 210T. The upper plate-like member 220T has a configuration similar to that of the lower plate-like member 220B, and is constituted by an elastic member. The upper plate-like member 220T is formed, for example, in a wavelike shape in the cross-sectional view shown in FIG. 24. The upper plate-like member 220T is arranged such that top portions 220Ta of the wavelike shape are in contact with the upper insulator 210T. Moreover, top portions 220Tb of the wavelike shape of the upper plate-like member 220T are in contact with the upper plate 230T.

The material, the thermal expansion rate, and the like of the upper plate-like member 220T are as defined in the embodiment above, and the elastic force of the lower plate-like member 220B is larger than the elastic force of the upper plate-like member 220T (the elastic force of the lower plate-like member 220B>the elastic force of the upper plate-like member 220T). This relationship can be achieved by setting the thermal expansion rate of the lower plate-like member 220B to be larger than the thermal expansion rate of the upper plate-like member 220T.

As in the case shown in FIG. 4, the first gas supply portion 61 and the first gas discharge portion 62 pass through through holes 81 a of a collector 81. Outer peripheral walls 415 are provided on the top face of a first plate-like body 1 adjacent to this collector 81 so as to extend along the outer periphery of the first gas supply portion 61 and the outer periphery of the first gas discharge portion 62. The outer peripheral walls 415 extend upward from the top face of the above-mentioned first plate-like body 1 to the vicinity of the upper plate 230T through the through holes 81 a of the collector 81. Accordingly, circular holes corresponding to the outer peripheral walls 415 are formed in the upper plate-like member 220T at the positions at which the outer peripheral walls 415 are located.

The upper cover 201 and the lower cover 203 are fastened to each other through adhesion, welding, bonding, fitting, or the like of the inner peripheral face of the first end portion 201 c of the upper cover 201 and the first end portion 203 b of the lower cover 203 that is performed in the state in which the electrochemical element stack S, the upper insulator 210T, the lower insulator 210B, the upper plate-like member 220T, the lower plate-like member 220B, the upper plate 230T, the lower plate 230B, and the like are sandwiched between the upper cover 201 and the lower cover 203 from above and below. During this fastening, the upper cover 201 and the lower cover 203 are coupled to each other while applying predetermined clamping pressure to the electrochemical element stack S and the like. That is, in the state in which the upper cover 201 and the lower cover 203 are coupled to each other, predetermined clamping pressure is applied to the electrochemical element stack S, the upper insulator 210T, the lower insulator 210B, the upper plate-like member 220T, the lower plate-like member 220B, the upper plate 230T, and the lower plate 230B. This clamping pressure is applied by causing predetermined compressional deformation L of the upper plate-like member 220T and the lower plate-like member 220B. Regarding the compressional deformation L in this case, both the upper plate-like member 220T and the lower plate-like member 220B are taken into consideration.

Furthermore, the pressing mechanisms 400 can press the first gas supply portion 61 and the first gas discharge portion 62 toward the electrochemical element stack S, namely downward in the stacking direction. The configuration of the pressing mechanism 400 is the same as that in the embodiment above.

(2-2) Functions of Plate-Like Member and Pressing Mechanism

Next, the functions of the plate-like members (upper plate-like member 220T and lower plate-like member 220B) 220 and the pressing mechanism 400 will be further described.

The upper plate-like member 220T and the lower plate-like member 220B, which are each constituted by a thermally expandable member, are arranged on the top flat face and the bottom flat face of the electrochemical element stack S, and elastically support the electrochemical element stack S due to the upper and lower plates 230 applying predetermined clamping pressure thereto. The upper plate-like member 220T presses and supports the electrochemical element stack S from above in the stacking direction, and the lower plate-like member 220B presses and supports the electrochemical element stack S from below in the stacking direction. For example, a clearance between the electrochemical element stack S and the container 200 that has increased in size due to thermal expansion is compensated with the upper plate-like member 220T and the lower plate-like member 220B that have thermally expanded, and thus appropriate clamping pressure is applied to the electrochemical element stack S.

Here, as described above, the lower plate-like member 220B has a thermal expansion rate larger than the thermal expansion rate of the upper plate-like member 220T. Accordingly, a pressing force applied to the electrochemical element stack S from below in the stacking direction by the lower plate-like member 220B is larger than a pressing force applied to the electrochemical element stack S from above in the stacking direction by the upper plate-like member 220T. Therefore, the electrochemical element stack S is pressed upward from below with a pressing force larger than a pressing force applied thereto from above.

Moreover, in the pressing mechanism 400, when the second screw member 403 is screwed into the first screw member 401, the second screw member 403 is thrusted downward in the stacking direction. Thus, the second screw member 403 thrusts the first gas supply portion 61 and the plurality of first annular sealing portions 42 downward in the stacking direction. Similarly, the first gas discharge portion 62 and the plurality of second annular sealing portions 52 are pressed downward in the stacking direction by operating the pressing mechanism 400.

The regions that extend in the stacking direction and are respectively provided with the first gas supply portion 61 and the first gas discharge portion 62 are pressed upward from below in the stacking direction with a larger pressing force due to the relationship “the elastic force of the lower plate-like member 220B>the elastic force of the upper plate-like member 220T”. Moreover, these regions are pressed downward from above in the stacking direction by the pressing mechanisms 400. That is, the plurality of first annular sealing portions 42 and the plurality of second annular sealing portions 52 are pressed from below in the stacking direction by the lower plate-like member 220B, while being pressed from above in the stacking direction by the pressing mechanisms 400. Accordingly, generation of a gap between the first annular sealing portion 42 and another member and a gap between the second annular sealing portion 52 and another member is suppressed, thus making it possible to suppress leakage of the first gas.

Predetermined clamping pressure is applied to the region in the electrochemical element stack S that is provided with the electrochemical reaction portions 3, due to the upper cover 201 and the lower cover 203 pressing the upper insulator 210T, the lower insulator 210B, the upper plate-like member 220T, the lower plate-like member 220B, the upper plate 230T, the lower plate 230B and the like.

It should be noted that, as in the case of (1) above, the pressing mechanisms 400 can also be omitted from the configuration shown in FIG. 24. Even if the pressing mechanisms 400 are omitted, the electrochemical element stack S will be pressed upward from below in the stacking direction with a larger pressing force because the elastic force of the lower plate-like member 220B is larger than the elastic force of the upper plate-like member 220T. Accordingly, the electrochemical element stack S, including the regions on which the first annular sealing portions 42 and the second annular sealing portions 52 are present, is pressed upward from below in the stacking direction. Thus, leakage of the first gas through a gap between the first annular sealing portion 42 and another member and a gap between the second annular sealing portion 52 and another member can be suppressed. Moreover, as described above, the electrochemical element stack S is pressed by the lower plate-like member 220B toward the piping including the first gas supply portion 61, the first gas discharge portion 62, and the like to which the first annular sealing portion 42 and the second annular sealing portion 52 are coupled. The connection positions where the first annular sealing portion 42 and the second annular sealing portion 52 are connected to the piping can be substantially fixed. Therefore, the first annular sealing portion 42 and the second annular sealing portion 52 can be fixed to the piping through welding or the like.

The upper plate-like member 220T can be modified as in the cases of the above-described lower plate-like members 220B shown in FIGS. 5, 6, and the like.

(3) In the embodiment above, the first gas supply portion (flowing pipe) 61 and the first gas discharge portion (flowing pipe) 62 are connected to the top flat face (second flat face) of the electrochemical element stack S. On the other hand, the lower plate-like member 220B is provided along the bottom flat face (first flat face) of the electrochemical element stack S. However, there is no limitation to this configuration as long as the first annular sealing portions 42 and the second annular sealing portions 52 are pressed toward the piping including the first gas supply portion 61, the first gas discharge portion 62, and the like. For example, it is sufficient that, in the electrochemical element stack S, a side on which the first gas supply portion (flowing pipe) 61 and the first gas discharge portion (flowing pipe) 62 are connected and a side on which the plate-like member is provided are opposite to each other. Accordingly, a configuration is also possible in which the first gas supply portion (flowing pipe) 61 and the first gas discharge portion (flowing pipe) 62 are connected to the bottom flat face (first flat face) of the electrochemical element stack S, and the upper plate-like member 220T is provided along the top flat face (second flat face) thereof.

(4) In the embodiment above, the pressing mechanism 400 includes a mechanism for thrusting the second screw member 403 into the first screw member 401 by screwing the second screw member 403 into the first screw member 401. However, the pressing mechanism 400 is not limited to the configuration above as long as the first annular sealing portions 42 and the second annular sealing portions 52 can be pressed thereby. The pressing mechanism 400 may have a configuration in which the second screw member 403 is inserted into the cylindrical first screw member 401 and is fixed by friction or the like at a thrusting position, for example. Also, the pressing mechanism 400 may include a mechanism for thrusting the second screw member 403 on the first screw member 401 by screwing the internal thread portion formed on the second screw member 403 onto the external thread portion formed on the first screw member 401.

(5) In the embodiment above, the plate-like member 220 is applied to the electrochemical module M in which the electrochemical elements A are SOFCs. However, the above-mentioned plate-like member 220 can also be applied to SOECs (Solid Oxide Electrolyzer Cells), secondary cells, and the like.

(6) Although the electrochemical elements A are used in a solid oxide fuel cell serving as the electrochemical device 100 in the embodiment above, the electrochemical elements A can also be used in a solid oxide electrolysis cell, an oxygen sensor using a solid oxide, and the like. The electrochemical elements A can also be used alone as well as used in combination of two or more for the electrochemical element stack S or the electrochemical module M.

That is, in the embodiment above, a configuration that can improve the efficiency of converting chemical energy such as fuel into electric energy is described.

In other words, in the embodiment above, the electrochemical elements A and the electrochemical module M are operated as fuel cells, and hydrogen gas flows to the electrode layer 31 and oxygen gas flows to the counter electrode layer 33. Accordingly, oxygen molecules O₂ react with electrons e⁻ to produce oxygen ions O²⁻ in the counter electrode layer 33. The oxygen ions O²⁻ move to the electrode layer 31 through the electrolyte layer 32. In the electrode layer 31, hydrogen molecules H₂ react with oxygen ions O²⁻ to produce water H₂O and electrons e⁻. With these reactions, an electromotive force is generated between the electrode layer 31 and the counter electrode layer 33, and power is generated.

On the other hand, when the electrochemical elements A and the electrochemical module M are operated as electrolysis cells, gas containing water vapor and carbon dioxide flows to the electrode layer 31, and a voltage is supplied between the electrode layer 31 and the counter electrode layer 33. As a result, in the electrode layer 31, electrons e⁻ react with water molecules H₂O and carbon dioxide molecules CO₂ to produce hydrogen molecules H₂, and carbon monoxide CO and oxygen ions O²⁻. The oxygen ions O²⁻ move to the counter electrode layer 33 through the electrolyte layer 32. In the counter electrode layer 33, the oxygen ions O²⁻ release electrons and oxygen molecules O₂ are produced. Through the reactions above, water molecules H₂O are electrolyzed into hydrogen molecules H₂ and oxygen molecules O₂, and in the case where gas containing carbon dioxide molecules CO₂ flows, carbon dioxide molecules CO₂ are electrolyzed into carbon monoxide molecules CO and oxygen O₂.

In the case where gas containing water vapor and carbon dioxide molecules CO₂ flows, a fuel converter 25 (FIG. 26) that synthesizes various compounds such as hydrocarbons from hydrogen, carbon monoxide, and the like generated through the above-mentioned electrolysis in the electrochemical elements A and the electrochemical module M can be provided. With the fuel supply unit (not shown), hydrocarbon and the like produced by this fuel converter 25 can be extracted from the system and the device and separately used as fuel or the like. Moreover, a configuration is also possible in which hydrogen or carbon monoxide is converted into chemical raw material in the fuel converter 25 and then the resulting chemical raw material is used.

FIG. 26 shows examples of the energy system Z and the electrochemical device 100 in the case where the electrochemical reaction portions 3 are operated as electrolysis cells. In this system, supplied water and carbon dioxide are electrolyzed in the electrochemical reaction portion 3 to produce hydrogen, carbon monoxide, and the like. Furthermore, in the fuel converter 25, hydrocarbons and the like are synthesized. By employing the configuration in which the heat exchanger 24 shown in FIG. 26 is operated as a waste heat utilization system that performs heat exchange between the water and the reaction heat produced by the reaction in the fuel converter 25 to vaporize the water, and the heat exchanger 23 shown in FIG. 26 is operated as a waste heat utilization system that performs heat exchange between water vapor and carbon dioxide, and waste heat produced by the electrochemical elements A to preheat the water vapor and the carbon dioxide, the energy efficiency can be improved.

Moreover, a power converter 93 supplies power to the electrochemical elements A. Accordingly, as mentioned above, the electrochemical elements A function as electrolysis cells.

Therefore, with the above-mentioned configuration, an electrochemical device 100, an energy system Z, and the like that can improve the efficiency of converting electric energy into chemical energy such as fuel can be provided.

(7) In the embodiment above, a composite material such as NiO-GDC, Ni-GDC, NiO—YSZ, Ni—YSZ, CuO—CeO₂, or Cu—CeO₂ is used as the material of the electrode layer 31, and a complex oxide such as LSCF or LSM is used as the material of the counter electrode layer 33. With this configuration, the electrode layer 31 serves as a fuel electrode (anode) when hydrogen gas is supplied thereto, and the counter electrode layer 33 serves as an air electrode (cathode) when air is supplied thereto, thus making it possible to use the electrochemical element A as a cell for a solid oxide fuel cell. It is also possible to change this configuration and thus configure an electrochemical element A such that the electrode layer 31 can be used as an air electrode and the counter electrode layer 33 can be used as a fuel electrode. That is, a complex oxide such as LSCF or LSM is used as the material of the electrode layer 31, and a composite material such as NiO-GDC, Ni-GDC, NiO—YSZ, Ni—YSZ, CuO—CeO₂, or Cu—CeO₂ is used as the material of the counter electrode layer 33. With this configuration, the electrode layer 31 serves as an air electrode when air is supplied thereto, and the counter electrode layer 33 serves as a fuel electrode when hydrogen gas is supplied thereto, thus making it possible to use the electrochemical element A as a cell for a solid oxide fuel cell.

(8) In the embodiment above, the electrode layer 31 is arranged between the first plate-like body 1 and the electrolyte layer 32, and the counter electrode layer 33 is arranged on the side of the electrolyte layer 32 opposite to the first plate-like body 1. A configuration is also possible in which the electrode layer 31 and the counter electrode layer 33 are provided in an inversed arrangement. Specifically, a configuration is also possible in which the counter electrode layer 33 is arranged between the first plate-like body 1 and the electrolyte layer 32, and the electrode layer 31 is arranged on the side of the electrolyte layer 32 opposite to the first plate-like body 1. In this case, a change also needs to be made regarding the supply of gas to the electrochemical elements A.

That is, regarding the order of the electrode layer 31 and the counter electrode layer 33, and which is employed a configuration in which the first gas is reducing component gas and the second gas is oxidative component gas or a configuration in which the first gas is oxidative component gas and the second gas is reducing component gas, various aspects can be employed as long as the electrode layer 31 and the counter electrode layer 33 are arranged such that the first gas and the second gas are supplied thereto so as to appropriately react with each other.

(9) Although the electrochemical reaction portion 3 covering the gas-permeable portion 1A is provided on a side of the first plate-like body 1 opposite to the second plate-like body 2 in the embodiment above, the electrochemical reaction portion 3 may also be provided on the second plate-like body 2 side of the first plate-like body 1. That is, the present invention can be achieved even when a configuration is employed in which the electrochemical reaction portion 3 is arranged in the internal passage A1.

(10) In the descriptions above, the electrochemical element stack S is clamped using the container (the first clamping portion, the second clamping portion) 200. However, the container 200 need not be used as long as the electrochemical element stack S can be clamped. For example, the electrochemical element stack S may also be clamped between end plates (a first clamping portion, a second clamping portion) or the like.

(11) Although the first penetrated portion 41 and the second penetrated portion 51 are provided as a pair at the two end portions of the rectangular plate-like support in the embodiment above, there is no limitation to the configuration in which they are provided at the two end portions. A configuration may also be employed in which two or more pairs are provided. The first penetrated portion 41 and the second penetrated portion 51 need not be provided as a pair. Accordingly, one or more first penetrated portions 41 and one or more second penetrated portions 51 can be provided.

Furthermore, the shape of the plate-like support is not limited to a rectangular shape, and various shapes such as a square shape and a circular shape can be employed.

(12) There is no limitation on the shapes of the first annular sealing portion 42 and the second annular sealing portion 52 as long as a configuration is obtained in which the first penetrated portion 41 and the second penetrated portion 51 are in communication with each other and leakage of gas can be prevented. That is, it is sufficient that the first annular sealing portion 42 and the second annular sealing portion 52 have an endless shape provided with an opening portion that is in communication with the penetrated portion therein, and are configured to seal a gap between the adjacent electrochemical elements A. The first annular sealing portion 42 and the second annular sealing portion 52 have, for example, an annular shape. The annular shape may be any of an annular circle, an annular ellipse, an annular square, an annular polygon, and the like.

(13) In the description above, the plate-like support 10 includes the first plate-like body 1 and the second plate-like body 2. Separate plate-like bodies may be used to form the first plate-like body 1 and the second plate-like body 2, or a single plate-like body as shown in FIG. 25 may be used to form the first plate-like body 1 and the second plate-like body 2. In the case shown in FIG. 25, the first plate-like body 1 and the second plate-like body 2 are stacked by folding a single plate-like body. The first plate-like body 1 and the second plate-like body 2 are integrated by, for example, welding the peripheral portions 1 a. It should be noted that a continuous seamless plate-like body may be used to form the first plate-like body 1 and the second plate-like body 2 and may be folded to be shaped as shown in FIG. 25.

Moreover, as described later, the second plate-like body 2 may be constituted by a single member or two or more members. Similarly, the first plate-like body 1 may be constituted by a single member or two or more members.

(14) The above-mentioned second plate-like body 2 forms the internal passage A1 together with the first plate-like body 1. The internal passage A1 includes the distribution portion A12, a plurality of auxiliary passages A11, and the confluence portion A13. As shown in FIG. 9, the first gas supplied to the distribution portion A12 is distributed and supplied to the plurality of auxiliary passages A11, and merges in the confluence portion A13 after leaving the auxiliary passages A11 through the exits. Accordingly, the first gas flows in a gas-flowing direction from the distribution portion A12 toward the confluence portion A13.

The plurality of auxiliary passages A11 is formed by shaping the portion of the second-plate like body 2 other than the portions corresponding to the distribution portion A12 and the confluence portion A13 into a wavelike shape. As shown in FIG. 13, the plurality of auxiliary passages A11 form a wavelike shape in a cross-sectional view taken in a flow-intersection direction that intersects the direction in which the first gas flows. The plurality of auxiliary passages A11 are formed by extending the wavelike plate in the gas flowing direction shown in FIG. 9. The plurality of auxiliary passages A11 may be formed of a continuous wavelike plate-like body or two or more wavelike plate-like bodies between the distribution portion A12 and the confluence portion A13. For example, the plurality of auxiliary passages A11 may be formed of two or more wavelike plate-like bodies that are separate from each other in a direction extending in the gas flowing direction, or two or more wavelike plate-like bodies that are separate from each other in a direction extending in the flow-intersection direction.

As shown in FIG. 13, the plurality of auxiliary passages A11 form a wavelike shape by repeatedly forming crests and troughs with the same shape. However, the second plate-like body 2 may include a plate-like portion in the region provided with the plurality of auxiliary passages A11. For example, the plurality of auxiliary passages A11 may be formed by forming plate-like portions and protruding portions alternately. The protruding portions can be used as portions in which a fluid such as the first gas flows.

(15) The portion of the above-mentioned second plate-like body 2 corresponding to the plurality of auxiliary passages A11 need not be formed in a wavelike shape as a whole, and it is sufficient that at least a portion thereof is formed in a wavelike shape. For example, the second plate-like body 2 may be formed such that a portion in the gas flowing direction has a flat shape and the portion other than the flat portion has a wavelike shape, between the distribution portion A12 and the confluence portion A13. The second plate-like body 2 may also be formed such that a portion in the flow-intersection direction has a flat shape and the portion other than the flat portion has a wavelike shape.

(16) A structure that can improve the power generation efficiency can be provided in the above-mentioned internal passage A1. The following is a description of such a configuration. A description of portions that are the same as those of the embodiment above is simplified or omitted.

(I) Specific Configuration of Electrochemical Module M

Next, the specific configuration of the electrochemical module M will be described with reference to FIGS. 27 to 44 and the like. The electrochemical module M includes the electrochemical element stack S shown in FIG. 4.

As shown in FIGS. 27 to 44 and the like, the stacking direction of the electrochemical element stack S includes the +Z direction and −Z direction (Z direction). The direction in which the first gas flows between the first plate-like body 1 and the second plate-like body 2 from the first gas supply portion 61 side toward the first gas discharge portion 62 side, and, similarly, the direction in which the second gas flows between the first plate-like body 1 and the second plate-like body 2 from the second gas supply portion 71 side toward the second gas discharge portion 72 side include the +X direction and −X direction (X direction) intersecting the +Z direction and −Z direction (Z direction). The direction that intersects the +Z direction and −Z direction (Z direction) and the +X direction and −X direction (X direction) includes the +Y direction and −Y direction (Y direction). The XZ plane, the XY plane, and the YZ plane are substantially orthogonal to one another.

As shown in FIGS. 4, 27, and the like, the electrochemical module M includes: the first gas supply portion 61 for supplying first gas to the internal passages A1 via the supply passage 4; the first gas discharge portion 62 for discharging the first gas used in a reaction; the second gas supply portion 71 for supplying second gas from the outside to the flowing portions A2; the second gas discharge portion 72 for discharging the second gas used in a reaction; and an output portion 8 to which output generated by an electrochemical reaction in the electrochemical reaction portion 3 is provided, wherein the distribution chamber 9 for distributing and supplying the second gas supplied from the second gas supply portion 71, to the flowing portions A2 is provided inside the container 200.

Accordingly, in the electrochemical module M, the fuel gas (also referred to as the “first gas”) is supplied from the first gas supply portion 61 and air (also referred to as the “second gas”) is supplied from the second gas supply portion 71, so that the fuel gas enters as indicated by dashed arrows and the air enters as indicated by solid arrows as shown in FIGS. 4, 27, and the like.

The fuel gas supplied from the first gas supply portion 61 is introduced into the supply passage 4 through the first penetrated portion 41 of the topmost electrochemical element A of the electrochemical element stack S, and flows from the supply passage 4 partitioned by the first annular sealing portions 42 into the internal passage A1 in all of the electrochemical elements A. Moreover, the air supplied from the second gas supply portion 71 temporarily flows into the distribution chamber 9, and then flows into the flowing portions A2 formed between the electrochemical elements A. In this embodiment, the flowing direction in which the fuel gas flows in the internal passage A1 along the flat face of the plate-like support 10 is a direction extending from the +X side toward the −X side. Similarly, the flowing direction in which the air flows in the flowing portion A2 along the flat face of the plate-like support 10 is a direction extending from the +X side toward the −X side.

Incidentally, when the second plate-like body 2 (a portion of a plate-like support 10) is considered as a base, the internal passage A1 is formed between the first plate-like body 1 (a portion of the plate-like support 10) and the second plate-like body 2 at a position at which a portion of the second plate-like body 2 with a wavelike plate-like shape bulges from the first plate-like body 1, and such a portion comes into contact with the electrochemical reaction portion 3 of the adjacent electrochemical element A and can be electrically connected thereto. On the other hand, a portion of the second plate-like body 2 with a wavelike plate-like shape that is in contact with the first plate-like body 1 is electrically connected to the first plate-like body 1, and the flowing portion A2 is formed between the second plate-like body 2 and the electrochemical reaction portion 3 of the adjacent electrochemical element A.

Portions of FIG. 43 and the like show a cross section of an electrochemical element A including the internal passage A1 and a cross section of an electrochemical element A including the flowing portion A2 that are aligned for the sake of convenience. The fuel gas supplied from the first gas supply portion 61 reaches the distribution portion A12 (see FIGS. 27 to 30 and the like), flows and spreads in the width direction of one end portion via the distribution portion A12, and reaches auxiliary passages A11 of the internal passage A1 (see FIGS. 27 to 30 and the like).

As shown in FIG. 27 and the like, the internal passage A1 includes the distribution portion A12, the plurality of auxiliary passages A11, and the confluence portion A13, which will be described later. The internal passage A1 further includes a supply buffer portion 144 provided between the distribution portion A12 and the plurality of auxiliary passages A11, and a discharge buffer portion 154 provided between the plurality of auxiliary passages A11 and the confluence portion A13.

The internal passage A1 is formed by a space formed between the first plate-like body 1 and the second plate-like body 2, which are opposed to each other. In this embodiment, the first plate-like body 1 has a flat shape and is provided with the gas-permeable portion 1A, which will be described later. The second plate-like body 2 includes portions protruding upward with respect to the stacking direction and portions recessed downward. Accordingly, when the first plate-like body 1 and the second plate-like body 2 are combined in a state of being opposed to each other, the portions of the second plate-like body 2 protruding upward come into contact with the first plate-like body 1. A space partitioned into the distribution portion A12, the supply buffer portion 144, the plurality of auxiliary passages A11, the discharge buffer portion 154, the confluence portion A13, and the like is formed by the portions of the second plate-like body 2 recessed downward and the first plate-like body 1.

A supply structure 140 is provided between the distribution portion A12 and the plurality of auxiliary passages A11 in a direction extending in the direction in which the fuel gas flows (the +X direction and −X direction (X direction)), which will be described in detail later. Due to the supply structure 140, the fuel gas is temporarily stored in the distribution portion A12, and supply of the fuel gas from the distribution portion A12 to the plurality of auxiliary passages A11 is limited.

A discharge structure 150 is provided between the plurality of auxiliary passages A11 and the confluence portion A13 in a direction extending in the direction in which the fuel gas flows. Due to the discharge structure 150, discharge of the fuel gas from the plurality of auxiliary passages A11 to the confluence portion A13 is limited.

The fuel gas flows in the first gas supply portion 61, the first annular sealing portion 42, the first penetrated portion 41, and the like, and is supplied to the distribution portion A12 of each electrochemical element A. The fuel gas supplied to the distribution portion A12 is temporarily stored in the distribution portion A12 due to the supply structure 140. Then, the fuel gas is introduced into the plurality of auxiliary passages A11 from the distribution portion A12.

The fuel gas that has entered the auxiliary passages A11 flows in the auxiliary passages A11, and enters the electrode layer 31 and the electrolyte layer 32 through the gas-permeable portion 1A. Moreover, the fuel gas further flows in the auxiliary passages A11 together with the fuel gas used in an electrochemical reaction. After reaching the ends of the plurality of auxiliary passages A11 in the flowing direction, the fuel gas flows into the confluence portion A13 in a state in which flowing into the confluence portion A13 is partially limited due to the discharge structure 150. The fuel gas that has entered the confluence portion A13 flows in the confluence portion A13, the second penetrated portion 51, and the second annular sealing portion 52, and the like. Then, the fuel gas is discharged to the outside from the first gas discharge portion 62 together with the fuel gas used in an electrochemical reaction in other electrochemical elements A.

On the other hand, the air supplied from the second gas supply portion 71 enters the flowing portions A2 via the distribution chamber 9, and then can enter the counter electrode layers 33 and the electrolyte layers 32. Moreover, the air further flows in the flowing portions A2 along the electrochemical reaction portions 3 together with air used in an electrochemical reaction, and is discharged from the second gas discharge portion 72 to the outside.

With this configuration, the electrochemical elements A are connected in series between the collectors 81 and 82 due to the contact between the second plate-like body 2 and the electrochemical reaction portion 3 of the adjacent electrochemical elements A, and thus power generated following the fuel gas flow and the air flow in the electrochemical reaction portions 3 is extracted from the output portion 8 as composite output.

The configuration of the electrochemical element stack S will be described later in detail.

(II) Configurations of Internal Passage and Second Plate-Like Body

The configuration of the internal passage A1 formed by arranging the first plate-like body 1 and the second plate-like body 2 in a state of being opposed to each other will be further described.

In this embodiment, the internal passage A1 is formed by the inner faces of the first plate-like body 1 having a flat shape and the second plate-like body 2 formed in an uneven shape including portions protruding upward (in the +Z direction) in the stacking direction or portions recessed downward (in the −Z direction) in the stacking direction, the first plate-like body 1 and the second plate-like body 2 being combined in a state of being opposed to each other. The internal passage A1 includes the distribution portion A12, the supply buffer portion 144, the plurality of auxiliary passage A11, the discharge buffer portion 154, and the confluence portion A13. Moreover, the internal passage A1 further includes supply passing portions 141 (portions of the supply structure 140) and discharge passing portions 151 (portions of the discharge structure 150) through which the first gas passes.

It should be noted that the structure on the supply passage 4 side on which the first gas supply portion 61, the first annular sealing portion 42, the first penetrated portion 41, and the like are provided and the structure on the discharge passage 5 side on which the first gas discharge portion 62, the second annular sealing portion 52, the second penetrated portion 51, and the like are provided are symmetrical to each other. FIGS. 28 to 30, FIGS. 32 to 35, and the like show cross-sectional views of the discharge passage 5 side on which the first gas discharge portion 62, the second annular sealing portion 52, the second penetrated portion 51, and the like are provided. On the other hand, FIGS. 36 to 42 and the like show cross-sectional views of the supply passage 4 side on which the first gas supply portion 61, the first annular sealing portion 42, the first penetrated portion 41, and the like are provided. In the cross-sectional views of the discharge passage 5 side shown in FIGS. 28 to 30, FIGS. 32 to 35, and the like, the first gas flows in the direction in which the first gas is discharged from the plurality of auxiliary passages A11 to the second penetrated portion 51 and the like via the confluence portion A13. On the other hand, in the cross-sectional views of the supply passage 4 side shown in FIGS. 36 to 42 and the like, the first gas flows in the direction in which the first gas is supplied from the distribution portion A12 to the plurality of auxiliary passages A11 via the first penetrated portion 41 and the like.

The distribution portion A12 is provided corresponding to each electrochemical element A. The distribution portion A12 is provided on the supply passage 4 side and serves as a buffer portion for supplying the first gas to each electrochemical element A. The distribution portion A12 is provided on the upstream side of the plurality of the auxiliary passages A11 in the internal passage A1 in the direction in which the first gas flows (in the direction from the +X side toward the −X side). As shown in FIGS. 27 and 42 and the like, the distribution portion A12 is provided with the first penetrated portion 41 that passes through the second plate-like body 2 at the substantially central portion in the direction intersecting the flowing direction (+Y direction and −Y direction (Y direction)) and in the flowing direction (+X direction and −X direction (X direction)). The first gas flows in the first gas supply portion 61, the first annular sealing portion 42, the first penetrated portion 41, and the like and is supplied to the distribution portion A12 of each electrochemical element A.

As shown in FIGS. 28 to 42 and the like, the first plate-like body 1 and the second plate-like body 2 are integrated by welding the edge portion at the peripheral portion 1 a of the first plate-like body 1 and the edge portion at the peripheral portion 1 a of the second plate-like body 2 to each other. The distribution portion A12 is formed by processing the second plate-like body 2 such that a portion thereof is recessed downward in the stacking direction (−Z direction) with respect to the peripheral portion 1 a. More specifically, the distribution portion A12 is formed such that the location in the stacking direction changes at supply preventing portions 142 (portions of the supply structure 140). That is, as shown in FIG. 39 and the like, the top face of the distribution portion A12 is located below the top faces of the supply preventing portions 142 in the stacking direction. The top faces of the supply preventing portions 142 are in contact with the bottom face of the first plate-like body 1. Accordingly, discharge, from the distribution portion A12, of the first gas introduced into the distribution portion A12 is limited due to the supply preventing portions 142 protruding upward in the stacking direction, and the first gas is temporarily stored in the distribution portion A12 formed in a recessed shape.

As shown in FIG. 27 and the like, the distribution portion A12 is elongated in the +Y direction and −Y direction (Y direction) as viewed from above. The length in the Y direction of the distribution portion A12 corresponds to the length in the Y direction of the region provided with the plurality of auxiliary passages A11 that are arranged in parallel at intervals in the Y direction.

As shown in FIGS. 27 to 44, and the like, the plurality of auxiliary passages A11 in which the first gas flows extend in the flowing direction, namely the +X direction and −X direction (X direction). As described above, the plurality of auxiliary passages A11 are arranged in parallel at intervals in the Y direction. As shown in FIGS. 27 to 44, and the like, the second plate-like body 2 includes a plurality of auxiliary passage forming portions 160 for forming the plurality of auxiliary passages A11, and a plurality of partitioning portions 161 that are each provided between the adjacent auxiliary passage forming portions 160 to separate the adjacent auxiliary passages A11. As shown in FIG. 43 and the like, the auxiliary passage forming portions 160 are formed in a recessed shape with a bottom face, and the top faces of the partitioning portions 161 are located above the bottom faces of the auxiliary passage forming portions 160 in the stacking direction. The top faces of the partitioning portions 161 are in contact with the bottom face of the first plate-like body 1. Accordingly, the auxiliary passages A11 are separate from one another, and the first gas flows in each of the auxiliary passages A11 in the flowing direction.

It should be noted that, in FIG. 27 and the like, the auxiliary passages A11 extend in the flowing direction from the vicinity of the supply structure 140 to the vicinity of the discharge structure 150. However, there is no limitation to this configuration, and the auxiliary passages A11 may also be formed in only a portion of the region between the vicinity of the supply structure 140 and the vicinity of the discharge structure 150. That is, the auxiliary passage forming portions 160 for forming the auxiliary passages A11 may also be arranged in only a portion of the region between the vicinity of the supply structure 140 and the vicinity of the discharge structure 150.

As shown in FIGS. 43 and 44, in the +Y direction and −Y direction (Y direction; the intersection direction intersecting the flowing direction), the length L3 of each partitioning portion 161 is smaller than the length L4 of each auxiliary passage forming portion 160 (L3<L4). When L3 is smaller than L4, as shown in FIG. 43 and the like, the contact area between the top face of the partitioning portion 161 and the bottom face of the first plate-like body 1 can be reduced. That is, a space in the auxiliary passage A11 facing the first plate-like body 1 provided with the gas-permeable portion 1A can be increased, thus making it possible to increase the amount of the first gas flowing from the auxiliary passage A11 to the electrochemical reaction portion 3.

As shown in FIG. 27, FIGS. 36 to 44, and the like, the second plate-like body 2 includes the supply structure 140 between the distribution portion A12 and the plurality of auxiliary passages A11 in a direction extending in the flowing direction (+X direction and −X direction (X direction)). Due to the supply structure 140, the first gas is temporarily stored in the distribution portion A12, and supply of the first gas from the distribution portion A12 to the plurality of auxiliary passages A11 is limited.

The supply structure 140 includes a plurality of supply passing portions 141 and a plurality of supply preventing portions 142. The first gas flows from the distribution portion A12 to the plurality of auxiliary passages A11 through the supply passing portions 141. The supply preventing portions 142 prevent the first gas from flowing from the distribution portion A12 to the plurality of auxiliary passages A11. As shown in FIG. 38 and the like, the top faces of the supply preventing portions 142 are located above the top faces of the supply passing portions 141 in the stacking direction, and are in contact with the bottom face of the first plate-like body 1. Accordingly, while the supply preventing portion 142 prevents the first gas in the distribution portion A12 from flowing in the flowing direction, the first gas flows to the plurality of auxiliary passages A11 through the supply passing portions 141 in the flowing direction.

In this embodiment, as shown in, for example, FIGS. 27 and 44, the supply preventing portions 142 are formed in a substantially rectangular shape. The rectangular supply preventing portions 142 are arranged in the +Y direction and −Y direction (Y direction) such that the long sides extend in the Y direction. The supply passing portions 141 are each provided between the adjacent supply preventing portions 142. That is, the supply passing portions 141 are each provided in the interval between the short sides of the adjacent supply preventing portions 142 that are opposed to each other.

As shown in FIG. 44, in the +Y direction and −Y direction (Y direction; the intersection direction intersecting the flowing direction), the length L2 of each supply preventing portion 142 is larger than the length L1 of each supply passing portion 141 (L2>L1). It is preferable that the length L1 of each supply passing portion 141 is smaller than the length L3 of each partitioning portion 161 (L1<L3). This configuration allows the first gas ejected from the distribution portion A12 through the supply passing portions 141 to collide against the end portions on the +X side of the partitioning portions 161 and to be temporarily stored in the supply buffer portion 144, which will be described later.

The relationship between L1 and L2 is determined depending on, for example, the amount of the first gas supplied to the distribution portion A12 per unit time, the amount of the first gas to be supplied to the plurality of auxiliary passages A11 per unit time, the number of the supply preventing portions 142, the length L3 in the Y direction of each partitioning portion 161, the length L4 in the Y direction of each auxiliary passage A11, and the like.

As described above, the auxiliary passages A11 are separated by the partitioning portions 161. In the flowing direction (+X direction and −X direction (X direction)), the plurality of partitioning portions 161 are arranged such that any of the partitioning portions 161 corresponds to one supply passing portion 141.

Moreover, in the flowing direction, the plurality of auxiliary passages A11 are arranged such that at least one of the auxiliary passages A11 corresponds to one supply preventing portion 142.

The first gas is introduced into the plurality of auxiliary passages A11 from the distribution portion A12 through the supply passing portions 141. With the above-mentioned configuration, any of the partitioning portions 161 corresponds to one supply passing portion 141 in the flowing direction, the first gas ejected from the distribution portion A12 into the supply passing portions 141 flows in the flowing direction and thus collides against the partitioning portions 161 protruding upward in the stacking direction. Due to the collision with the partitioning portions 161, the first gas flows in the intersection direction intersecting the flowing direction. That is, the first gas flowing from the distribution portion A12 through the supply passing portions 141 is not immediately introduced into the plurality of auxiliary passages A11, but collides against the partitioning portions 161 on the upstream side of the auxiliary passages A11 and flows in the intersection direction. Furthermore, the first gas flowing in the intersection direction does not return to the distribution portion A12 due to the supply preventing portions 142 protruding upward in the stacking direction, and is temporarily stored between the supply structure 140 and the plurality of auxiliary passages A11. Thereafter, the first gas flows along the ejection from the distribution portion A12 and is introduced into the plurality of auxiliary passages A11 formed by the plurality of auxiliary passage forming portions 160.

It should be noted that the region between the supply structure 140 and the plurality of auxiliary passages A11 in which the first gas is temporarily stored is the supply buffer portion 144.

In this embodiment, one of the partitioning portions 161 corresponds to one supply passing portion 141 in the flowing direction. However, there is no limitation to this configuration, and a plurality of partitioning portions 161 may correspond to one supply passing portion 141. A configuration may also be employed in which no partitioning portion 161 is correspond to one supply passing portion 141, and one partitioning portion 161 corresponds to another supply passing portion 141.

The supply preventing portion 142 is provided corresponding to the first penetrated portion 41 in the flowing direction. This makes it possible to reduce a possibility that the first gas flows to the plurality of auxiliary passages A11 immediately after being introduced into the distribution portion A12 from the first penetrated portion 41. Accordingly, the first gas can be temporarily stored in the distribution portion A12.

The number of the supply preventing portion 142 is, for example, two or more, but is not limited thereto. It is preferable to set the number of the supply preventing portions 142 in accordance with the number of the plurality of auxiliary passages A11.

In the description above, the supply preventing portions 142 are lined up in a row in the direction intersecting the flowing direction.

However, there is no limitation to this arrangement as long as the first gas can be temporarily stored in the distribution portion A12, and the first gas can be substantially uniformly supplied to the plurality of auxiliary passages A11. For example, a plurality of supply preventing portions 142 may deviate from the intersection direction. A plurality of supply preventing portions 142 may be arranged in the intersection direction or deviate from the intersection direction.

In the description above, the supply preventing portions 142 have a rectangular shape. However, the shape of the supply preventing portions 142 is not limited thereto as long as gas can be uniformly supplied from the distribution portion A12 to the plurality of auxiliary passages A11. For example, the supply preventing portions 142 may also be formed in various shapes such as a square shape, a circular shape, an elliptical shape, and a triangular shape.

It is preferable that, as in the case of the embodiments above shown in FIG. 27, FIG. 44, and the like, two of the plurality of supply preventing portions 142 are respectively provided at a position corresponding to the end portion on the +Y side of the distribution portion A12 and a position corresponding to the end portion on the −Y side thereof, but there is no limitation to this configuration. The first gas is distributed over the distribution portion A12 from the first penetrated portion 41 in the distribution portion A12 so as to spread in the space in the distribution portion A12, and collides against the end faces of the distribution portion A12. Accordingly, the first gas that has collided against the end faces of the distribution portion A12 may change its direction at the end faces and flow toward the plurality of auxiliary passages A11. Therefore, providing the supply preventing portions 142 at positions corresponding to the end portions of the distribution portion A12 makes it possible to reduce a possibility that the first gas immediately flows out of the distribution portion A12 into the plurality of auxiliary passages A11. This makes it possible to substantially uniformly supply the first gas from the distribution portion A12 to the auxiliary passages A11 as described later.

Next, the confluence portion A13 and the discharge structure 150 will be described. The confluence portion A13 and the discharge structure 150 respectively have the same structures as those of the distribution portion A12 and the supply structure 140.

The confluence portion A13 is provided on the discharge passage 5 side and serves as a buffer portion for discharging the first gas that has passed through the plurality of auxiliary passages A11. The confluence portion A13 is provided on the downstream side of the plurality of the auxiliary passages A11 in the internal passage A1 in the direction in which the first gas flows. As shown in FIGS. 27 and 44, and the like, the confluence portion A13 is provided with the second penetrated portion 51 that passes through the second plate-like body 2 at the substantially central portion in the flowing direction and the direction intersecting the flowing direction. The first gas that has passed through the plurality of auxiliary passages A11 is introduced into the confluence portion A13, and is discharged to the outside via the second penetrated portion 51, the second annular sealing portion 52, the first gas discharge portion 62, and the like.

The confluence portion A13 is formed such that the location in the stacking direction changes at discharge preventing portions 152 (portions of the discharge structure 150). That is, as shown in FIG. 32 and the like, the top face of the confluence portion A13 is located below the top faces of the discharge preventing portions 152 in the stacking direction. The top faces of the discharge preventing portions 152 are in contact with the bottom face of the first plate-like body 1. Accordingly, discharge of the first gas flowing from the plurality of auxiliary passages A11 to the confluence portion A13 is limited due to the discharge preventing portions 152 protruding upward in the stacking direction, and the first gas is temporarily stored in the plurality of auxiliary passages A11.

As shown in FIG. 27 and the like, the confluence portion A13 is elongated in the +Y direction and −Y direction (Y direction) as viewed from above. The length in the Y direction of the confluence portion A13 corresponds to the length in the Y direction of the region provided with the plurality of auxiliary passages A11 that are arranged in parallel at intervals in the Y direction.

As shown in FIG. 27, FIGS. 31 to 35, FIG. 44, and the like, the second plate-like body 2 includes the discharge structure 150 between the plurality of auxiliary passages A11 and the confluence portion A13 in a direction extending in the flowing direction (+X direction and −X direction (X direction)). Due to the discharge structure 150, discharge of the first gas from the plurality of auxiliary passages A11 to the confluence portion A13 is limited.

The discharge structure 150 includes a plurality of discharge passing portions 151 and a plurality of discharge preventing portions 152. The first gas flows from the plurality of auxiliary passages A11 to the confluence portion A13 through the discharge passing portions 151. The discharge preventing portions 152 prevent the first gas from flowing from the plurality of auxiliary passages A11 to the confluence portion A13. As shown in FIG. 32 and the like, the top faces of the discharge preventing portions 152 are located above the top faces of the discharge passing portions 151 in the stacking direction, and are in contact with the bottom face of the first plate-like body 1. Accordingly, while the discharge preventing portion 152 prevents the first gas in the plurality of auxiliary passages A11 from flowing in the flowing direction, the first gas flows to the confluence portion A13 through the discharge passing portions 151 in the flowing direction.

In this embodiment, as shown in, for example, FIGS. 27 and 44, the discharge preventing portions 152 are formed in a substantially rectangular shape as in the case of the supply preventing portions 142. The rectangular discharge preventing portions 152 are arranged in the +Y direction and −Y direction (Y direction) such that the long sides extend in the Y direction. The discharge passing portions 151 are each provided between the adjacent supply preventing portions 152. That is, the discharge passing portions 151 are each provided in the interval between the short sides of the adjacent discharge preventing portions 152 that are opposed to each other.

As shown in FIG. 44, in the +Y direction and −Y direction (Y direction; the intersection direction intersecting the flowing direction), the length L12 of each discharge preventing portion 152 is larger than the length L11 of each discharge passing portion 151 (L12>L11). It is preferable that the length L12 of each discharge preventing portion 152 is larger than the length L4 of each auxiliary passage forming portion 160 (L12>L4). This configuration allows the first gas flowing from the plurality of auxiliary passages A11 to the confluence portion A13 to collide against the discharge preventing portions 152 and to be temporarily stored in the discharge buffer portion 154, which will be described later.

The relationship between L11 and L12 is determined depending on, for example, the amount of the first gas supplied to the plurality of auxiliary passages A11 per unit time, the amount of the first gas to be discharged from the confluence portion A13 per unit time, the number of the discharge preventing portions 152, the length L3 in the Y direction of each partitioning portion 161, the length L4 in the Y direction of each auxiliary passage A11, and the like.

In the flowing direction, the plurality of auxiliary passages A11 are arranged such that at least one of the auxiliary passages A11 corresponds to one discharge preventing portion 152.

Moreover, in the flowing direction, the plurality of partitioning portions 161 are arranged such that any of the partitioning portions 161 corresponds to one discharge passing portion 151.

With the above-mentioned configuration, the first gas ejected from the plurality of auxiliary passages A11 flows in the flowing direction and thus collides against the discharge preventing portions 152 protruding upward in the stacking direction. Due to the collision with the discharge preventing portions 152, the first gas flows in the intersection direction intersecting the flowing direction. That is, the first gas that has passed through the plurality of auxiliary passages A11 is not immediately introduced into the confluence portion A13, but collides against the discharge preventing portions 152 on the upstream side of the confluence portion A13 and flows in the intersection direction. Thereafter, the first gas flows along the ejection from the plurality of auxiliary passages A11, passes through the discharge passing portions 151, and is introduced into the confluence portion A13.

It should be noted that the region between the plurality of auxiliary passages A11 and the discharge structure 150 in which the first gas is temporarily stored is the discharge buffer portion 154.

The discharge preventing portion 152 is provided corresponding to the second penetrated portion 51 in the flowing direction. This makes it possible to reduce a possibility that the first gas that has passed through the plurality of auxiliary passages A11 is immediately introduced into the confluence portion A13 and is discharged from the second penetrated portion 51. Accordingly, the first gas can be temporarily stored in the plurality of auxiliary passages A11.

The shapes, sizes, arrangements, numbers, and the like of the discharge passing portions 151 and the discharge preventing portions 152 are the same as those of the supply passing portions 141 and the supply preventing portions 142. For example, in FIG. 44, in the +Y direction and −Y direction (Y direction; the intersection direction intersecting the flowing direction), the length L12 of each discharge preventing portion 152 and the length L11 of each discharge passing portion 151 are respectively the same as the length L2 of each supply preventing portion 142 and the length L1 of each supply passing portion 141, which are described hereinbefore.

However, the shapes, sizes, arrangements, numbers, and the like of the discharge passing portions 151 and the discharge preventing portions 152 may be different from those of the supply passing portions 141 and the supply preventing portions 142. For example, the discharge passing portions 151 may be larger in size than the supply passing portions 141. Due to this configuration, the discharge pressure applied during discharge of the first gas from the plurality of auxiliary passages A11 to the confluence A13 may be smaller than the supply pressure during supply of the first gas from the distribution portion A12 to the plurality of auxiliary passages A11. The first gas is supplied from the distribution portion A12 to the plurality of auxiliary passages A11 with a certain level of supply pressure to make the flow distribution constant among the plurality of auxiliary passages A11, and the first gas can be smoothly introduced into the confluence portion A13 when discharged.

(a) Functions of Supply Structure and Discharge Structure

(a1) Functions of Supply Structure

Next, the functions of the supply structure 140 will be described.

The supply preventing portions 142 of the supply structure 140 having the above-mentioned configuration are provided between the distribution portion A12 and the plurality of auxiliary passages A11, and serve as barriers for flow of the first gas from the distribution portion A12 to the plurality of auxiliary passages A11. Accordingly, pressure loss of the first gas increases when the first gas flows from the distribution portion A12 into the plurality of auxiliary passages A11, and the first gas introduced into the distribution portion A12 is distributed over the distribution portion A12 so as to fill the distribution portion A12, and is thus temporarily stored therein. Accordingly, the overall pressure in the distribution portion A12 is substantially uniform (equal pressure). That is, differences in pressure between the distribution portion A12 and the plurality of auxiliary passages A11 are substantially the same. Then, the first gas is supplied from the distribution portion A12 to the plurality of auxiliary passages A11 through the supply passing portions 141, and therefore, the first gas is supplied to the auxiliary passages A11 with substantially equal pressure. Accordingly, the flow distribution (including the flow rate, the flow amount, the pressure, and the like) of the first gas in the flow direction is substantially uniform among the auxiliary passage A11.

Flow of the first gas from the distribution portion A12 is divided and introduced into the plurality of auxiliary passages A11. The flow distribution (including the flow rate, the flow amount, the pressure, and the like) of the first gas is also made substantially equal by a flow straightening effect due to the first gas flowing separately in a plurality of passages compared with the case where the first gas flows in an internal passage that is not provided with a plurality of passages.

As described above, the flow distribution of the first gas in the flowing direction is substantially uniform among the auxiliary passages A11. For example, when the auxiliary passages A11 are viewed at one position in the flowing direction, the flow rate, the flow amount, the pressure, and the like of the first gas in the intersection direction intersecting that position is substantially constant among the auxiliary passages A11. Accordingly, in the electrochemical reaction portion 3, a difference between a portion that is deficient in the first gas and a portion in which an excessive amount of the first gas flows can be reduced to improve the usage rate of the first gas in the overall electrochemical element A and thus improve the reaction efficiency of an electrochemical reaction.

It should be noted that, if the above-mentioned configuration that includes the distribution portion A12, the plurality of auxiliary passages A11, the supply structure 140, and the like is not employed, the auxiliary passages A11 may differ in the flow distribution of the first gas. That is, the flow rate of the first gas may be fast in a certain auxiliary passage A11, and the flow rate of the first gas may be slow in another auxiliary passage A11. In an auxiliary passage A11 in which the flow rate of the first gas is slow, the first gas is consumed in an electrochemical reaction and becomes insufficient. Accordingly, the concentration of the first gas decreases, and thus there is a risk that the electrode layer of the electrochemical reaction portion 3 is deteriorated due to oxidation, and the electrode performance and the mechanical strength are thus impaired. On the other hand, in an auxiliary passage A11 in which the flow rate of the first gas is fast, the first gas is discharged before consumed in an electrochemical reaction. That is, in the case where the first gas is fuel gas such as hydrogen, the fuel usage rate decreases because high-concentration first gas is discharged. To address the shortage of the first gas in an auxiliary passage A11 in which the flow rate of the first gas is slow, it is conceivable that the supply amount of the first gas supplied to each auxiliary passage A11 is increased. However, in this case, the amount of the first gas discharged before consumed in an electrochemical reaction is further increased in an auxiliary passage A11 in which the flow rate of the first gas is fast, and thus the fuel usage rate further decreases. Accordingly, when the flow distribution of the first gas varies among the auxiliary passages A11, the reaction efficiency of an electrochemical reaction decreases, and thus the power generation efficiency decreases.

(a2) Functions of Discharge Structure

Next, the functions of the discharge structure 150 will be described.

With the above-mentioned configuration, the supply structure 140 for supplying the first gas from the distribution portion A12 to the plurality of auxiliary passages A11 with substantially uniform flow distribution is provided, and in addition, the discharge structure 150 is provided at a position where the first gas enters the confluence portion A13 from the plurality of auxiliary passages A11. The plurality of auxiliary passages A11 are located between the supply structure 140 and the discharge structure 150, thus making it possible to make the flow distribution (including the flow rate, the flow amount, the pressure, and the like) of the first gas substantially uniform among the plurality of auxiliary passages A11 and to improve the reaction efficiency of an electrochemical reaction.

The following is a more specific description. The discharge preventing portions 152 of the discharge structure 150 having the above-mentioned configuration are provided between the plurality of auxiliary passages A11 and the confluence portion A13, and serve as barriers for flow of the first gas from the auxiliary passages A11 to the confluence portion A13. Accordingly, pressure loss of the first gas increases when the first gas flows from the plurality of auxiliary passages A11 into the confluence portion A13. Therefore, the first gas introduced into the plurality of auxiliary passages A11 is less likely to be immediately introduced into the confluence portion A13 from the plurality of auxiliary passages A11, and is distributed over the plurality of auxiliary passages A11 so as to fill the auxiliary passages A11. This makes it possible to make the flow distribution (including the flow rate, the flow amount, the pressure, and the like) of the first gas in the flowing direction substantially uniform among the plurality of auxiliary passages A11. Moreover, the first gas is distributed over the plurality of auxiliary passages A11 so as to fill the auxiliary passages A11, and therefore, an electrochemical reaction sufficiently occurs in the plurality of auxiliary passages A11. Accordingly, the reaction efficiency of an electrochemical reaction can be improved.

(17) In the embodiment above, the electrochemical device includes the electrochemical module M that includes the plurality of electrochemical elements A. However, a configuration in which a single electrochemical element is included can be applied to the electrochemical device of the embodiment above.

(18) In the embodiment above shown in FIG. 1, on the upper side in the stacking direction, the electrochemical element stack S is sandwiched by the upper plate 230T via the upper insulator 210T. Also, on the lower side in the stacking direction, the electrochemical element stack S is sandwiched by the lower plate-like member 220B and the lower plate 230B via the lower insulator 210B. The electrochemical element stack S, the upper insulator 210T, the upper plate 230T, the lower insulator 210B, the lower plate-like member 220B, and the lower plate 230B arranged as described above are housed in the container 200. The clamp in the claims corresponds to the upper and lower plates 230 and the container 200.

Moreover, in the case above shown in FIG. 5, on the upper side in the stacking direction, the electrochemical element stack S is sandwiched by the upper plate 230T via the upper insulator 210T. Also, on the lower side in the stacking direction, the electrochemical element stack S is sandwiched by the lower plate-like member 320B, the lower plate-like member 220B and the lower plate 230B via the lower insulator 210B. The electrochemical element stack S, the upper insulator 210T, the upper plate 230T, the lower insulator 210B, the lower plate-like member 320B, the lower plate-like member 220B, and the lower plate 230B arranged as described above are housed in the container 200. The clamp in the claims corresponds to the upper and lower plates 230 and the container 200.

Moreover, in the case above shown in FIG. 6, on the upper side in the stacking direction, the electrochemical element stack S is sandwiched by the upper insulator 210T. Also, on the lower side in the stacking direction, the electrochemical element stack S is sandwiched by the lower plate-like member 320B and the lower plate-like member 220B via the lower insulator 210B. The electrochemical element stack S, the upper insulator 210T, the lower insulator 210B, the lower plate-like member 320B, and the lower plate-like member 220B arranged as described above are housed in the container 200. The clamp in the claims corresponds to the upper and lower plates 230 and the container 200.

DESCRIPTION OF REFERENCE SIGNS

-   -   1: First plate-like body     -   1A: Gas-permeable portion     -   2: Second plate-like body     -   3: Electrochemical reaction portion     -   4: Supply passage     -   5: Discharge passage     -   9: Distribution chamber     -   10: Plate-like support     -   11: Through hole     -   31: Electrode Layer     -   32: Electrolyte layer     -   33: Counter electrode layer     -   41: First penetrated portion     -   42: First annular sealing portion     -   51: Second penetrated portion     -   52: Second annular sealing portion     -   61: First gas supply portion     -   62: First gas discharge portion     -   71: Second gas supply portion     -   72: Second gas discharge portion     -   100: Electrochemical device     -   200: Container     -   201: Upper cover     -   203: Lower cover     -   220: Plate-like Member     -   400: Pressing mechanism     -   401: First screw member     -   401 a: Internal thread portion     -   403: Second screw member     -   403 a: External thread portion     -   A: Electrochemical element     -   A: Second electrochemical element     -   A: First electrochemical element     -   A1: Internal passage     -   A11: Auxiliary passage     -   A12: Distribution portion     -   A13: Confluence portion     -   A2: Flowing portion     -   M: Electrochemical module     -   M1: Electrochemical module     -   M2: Electrochemical module 

1. An electrochemical module comprising: a stack obtained by stacking, in a predetermined stacking direction, a plurality of electrochemical elements having a configuration in which an electrolyte layer, and an electrode layer and a counter electrode layer that are respectively arranged on two sides of the electrolyte layer, are formed along a substrate via an annular sealing portion through which a first gas, which is one of a reducing component gas and an oxidative component gas, flows; a clamp comprising a first clamping portion for pressing a first flat face in the stacking direction of the stack and a second clamping portion for pressing a second flat face on a side opposite to the first flat face, the stack clamped between the first clamping portion and the second clamping portion; and an elastic first plate-like member arranged between the first flat face and the first clamping portion; and a flowing pipe connected to the second flat face in a state of being in communication with the annular sealing portion.
 2. The electrochemical module according to claim 1, further comprising an elastic second plate-like member arranged between the second flat face and the second clamping portion, wherein an elastic force of the first plate-like member is larger than an elastic force of the second plate-like member.
 3. The electrochemical module according to claim 1, further comprising a pressing mechanism that is provided on the second flat face side and presses a portion to which the annular sealing portion is attached against the clamp in the stacking direction.
 4. The electrochemical module according to claim 3, wherein the pressing mechanism presses, via the flowing pipe, a region in which the annular sealing portion is present in the stacking direction, and wherein a thermal expansion rate of the pressing mechanism is smaller than or equal to a thermal expansion rate of the flowing pipe.
 5. The electrochemical module according to claim 3, wherein the pressing mechanism comprises a first screw member provided on the first clamping portion, and a second screw member that can press the annular sealing portion in the stacking direction when screwed to the first screw member.
 6. The electrochemical module according to claim 5, wherein the first screw member is a cylindrical member provided with an internal thread portion on an inner circumferential face, wherein the second screw member is a cylindrical member provided with an external thread portion on an outer circumferential face, and wherein the external thread portion of the second screw member is screwed to the internal thread portion of the first screw member.
 7. The electrochemical module according to claim 6, wherein the pressing mechanism further comprises an electrical insulating sealing portion between the second screw member and the flowing pipe.
 8. The electrochemical module according to claim 1, wherein the substrate comprises an internal passage into which the first gas is introduced through the annular sealing portion, and a flowing portion through which a second gas that is the other of the reducing component gas and the oxidative component gas flows is formed between the electrochemical elements that are adjacent to each other in the stacking direction.
 9. The electrochemical module according to claim 1, wherein the substrate of each electrochemical element comprises a first penetrated portion for forming a supply passage through which the first gas flows, and wherein the first penetrated portion of each electrochemical element is in communication with an annular hole of the annular sealing portion provided between the adjacent electrochemical elements.
 10. The electrochemical module according to claim 9, wherein a first electrochemical element and a second electrochemical element of the plurality of electrochemical elements are adjacently stacked, wherein the substrate included in each electrochemical element comprises an internal passage into which the first gas flows through the annular sealing portion, wherein the substrate included in the first electrochemical element and the substrate included in the second electrochemical element are opposed to each other, an outer face of the substrate included in the first electrochemical element on which an electrochemical reaction portion is arranged is electrically connected to an outer face of the substrate included in the second electrochemical element that is different from an outer face on which the electrochemical reaction portion is arranged, and a flowing portion through which a second gas that is the other of the reducing component gas and the oxidative component gas flows is formed between the two adjacent outer faces along the two outer faces.
 11. The electrochemical module according to claim 10, wherein the substrate included in each electrochemical element is provided with a gas-permeable portion through which gas is permeable between the internal passage, which is located inside the substrate, and the outside, wherein the electrode layer, the electrolyte layer, and the counter electrode layer form an electrochemical reaction portion in a state in which the electrochemical reaction portion entirely or partially covers the gas-permeable portion, and wherein a first penetrated portion for forming a supply passage through which the first gas flows is formed between the outside in a surface penetration direction of the substrate and the internal passage.
 12. The electrochemical module according to claim 11, further comprising, in the flowing portion, a first annular sealing portion serving as the annular sealing portion for separating the first penetrated portion formed in each of the two outer faces from the flowing portion, and wherein the supply passage for supplying the first gas to the internal passage is formed by the first penetrated portion and the first annular sealing portion.
 13. The electrochemical module according to claim 11, wherein the substrate comprises a second penetrated portion for forming a discharge passage through which the first gas that has passed through the internal passage flows to the outside in a surface penetration direction of the substrate, wherein the electrochemical module further comprises in the flowing portion, a second annular sealing portion serving as the annular sealing portion for separating the second penetrated portion formed in each of the two outer faces from the flowing portion, and wherein the discharge passage through which the first gas that has passed through the internal passage flows is formed by the second penetrated portion and the second annular sealing portion.
 14. An electrochemical device comprising: the electrochemical module according to claim 1; a fuel converter that supplies gas containing a reducing component to the electrochemical module or a fuel converter that converts gas containing a reducing component generated in the electrochemical module.
 15. An electrochemical device comprising: the electrochemical module according to claim 1; and a power converter that extracts power from the electrochemical module or supplies power to the electrochemical module.
 16. An energy system comprising: the electrochemical device according to claim 14; and a waste heat utilization system that reuses heat discharged from the electrochemical device or a fuel converter.
 17. An energy system comprising: the electrochemical device according to claim 15; and a waste heat utilization system that reuses heat discharged from the electrochemical device or a fuel converter. 